REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, and BOATS => Build Threads => Topic started by: KensAuto on November 08, 2014, 10:58:51 PM

Title: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 08, 2014, 10:58:51 PM
                                                                                                             (2288)
Holton from Alligator called me last night when he got my email about the missing block off plate.
He's a good guy who cares about his customers and stuff exactly like this shows it.
He is sending me a coated block off plate 2nd day, so I'll have it by Friday

Here's some photos of what the EGR delete looks like
Missing are 4 hose clamps and the block off plate.
Of course the down pipe is a part of my installation since it will have to come out anyway, then why not replace it with the good stuff.
(http://i.imgur.com/Cmv8G2h.jpg)
(http://i.imgur.com/CuxqTpW.jpg)
(http://i.imgur.com/AjHH0Cr.jpg)
(http://i.imgur.com/l3Ypsi1.jpg)
(http://i.imgur.com/xUpuPbD.jpg)

Quote:
Originally Posted by L****
"What is the hose for in the 2nd post?"

First of all, my caveat
I have not installed this before and am no expert, in fact I am yet to reach novice status.
However
Over several conversations with Holton at Alligator who worked on development of this kit, with what I have and will shortly receive (the actual block off plate) can completely eliminate the EGR system. Those rubber hoses must (Speculation) be a part of the re-route of engine coolant that used to go to the EGR coolers, which have or will shortly find their way to the scrap metal recycler. You actually remove all that stuff in lieu of just blocking off and retaining the now unused components.

Posted by Guyton:
on the LMLs there's 2 coolant lines, one for the 1st cooler and one for the 2nd cooler. the blue line is for the 2nd cooler when it gets removed. the larger black line is for the first one that resembles the LMM EGR cooler if you was to delete it, almost the same as the LMMs but still way different.

as for your plate Don, you'll have it tomorrow buddy.


Quote:
Originally Posted by KensAuto 
"so you delete both coolers with the kit? that would sure free up some space!

and don, is that an 'uppipe' in the pic? u said something about a down pipe...or is that just part of the delete kit "

Yes, Ken you completely remove both coolers
And
Yes that is the supplied up pipe, passenger side
I mentioned a down pipe, because I will be removing the stocker and replacing it with the Alligator pipe at the same time, since I would have to remove it anyway.
The down pipe is not included in the kit, but something I've had for a month or so awaiting install.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 08, 2014, 11:18:09 PM
Update time gentlemens                                                                                               (2334)
(I know gentlemens is not proper, but I's using it anyway)
(I know I's is improper as well!)

Holton sent me this really cool looking block off plate. I will say that powder coating has gotten much better!
I haven't been able to get started on the EGR delete this week yet because of a rash of appointments and prior commitments. I think I am going to have to rent a car so that the truck can be down over a few days while I grab an hour here and there to get this stuff installed.
I ordered a bunch more stuff today so the projects are still coming at a good rate.
I will be installing the EGR block off
Then I decided to install an AMP Research step. However in keeping with my "fix everything even if it works fine" approach. I am going to modify the step. I plan to plate the underside with 3/16" steel to allow it to scrape ofer Kias and Daewoos and construct a steel support structure that the step can fold up against that will support the vehicle weight.
I finally decided to go with the electric step instead of my proposed rock rail/step system after suffering from a significant hearing loss in my right ear. That's the ear closest to my wife!
I also purchased the Cognito upper control arm, and Holton was able to source me some Rare parts tie rods which just came out as well. THe idea here will be to increase the front suspension travel. All those parts will allow significantly more droop-out.
Holton sold me some neat front sway bar end links which are super beefy.
Finally, I stepped up to the plate and purchased the Hypertech speedo in line calibrator. No one can tell me if it will work with the H&S XT Pro I run, so I'm going have to be the guinnie pig. At least when I get that sucker installed, we will finally know for sure.
Lastly I didn't order them yet, but I am looking at either some exhaust manifolds and up pipes or H2O/Methanol injection to keep things safe.
So that's the plan for the fall.
Oh
Forgot to mention
Road Armor finished the new rear bumper build minus the frame brackets. They will be shipping that to me and I'll finally be bolting that puppy on!
YIPPEE
So lots of good stuff on the horizion as long as I don't get lazy and slow down even more! 
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 12:42:05 PM
OK, boys and girls here we go again, day 1 of the EGR delete and Alligator down pipe install.
Day 1 because with all the appointments I am working around, it will probably take me until Saturday to finish everything.
This is a medium difficulty task which is very laborous. It's a case where there is quite a bit to do and it seems almost every fastner is a bear to get to. There are some I will need to remove tomorrow which I can't even see. I will have to remove them totally by feel.
I started by removing the right wheel well splash liner again and worked in that area for awhile.
(http://i.imgur.com/j6EkeE1.jpg)
(http://i.imgur.com/tQXPO6s.jpg)

In this area you basically remove everything you can get a wrench on.
(http://i.imgur.com/LZOMNlr.jpg)
(http://i.imgur.com/1YHAJbM.jpg)
(http://i.imgur.com/go241UN.jpg)
(http://i.imgur.com/K8mjbGy.jpg)

And then the passenger up-pipe lower flange bolts
(http://i.imgur.com/CT24KxZ.jpg)
(http://i.imgur.com/g6FmlUM.jpg)

With the bolts and the fuel injector removed, I moved up to the engine bay area. Beginning with the air filter inlet duct, my plan was to "work to uncover things." That meant getting the air duct out of there then move to the aluminum inlet "S" pipe
(http://i.imgur.com/Eh0HkzN.jpg)
(http://i.imgur.com/KVhK0iB.jpg)

Next I went for the turbo inlet assembly. That plastic elbow is held in place by another V-band clamp. It is very difficult to see so when I loosened it, I was not able to remove the elbow. So I then decided to remove the EGR hot air pipe to see if that freed up some room.
(http://i.imgur.com/hRWqwRX.jpg)
(http://i.imgur.com/4uGO25M.jpg)

The elbow was still loose but stuck so I thought I would try to remove the front of the two EGR coolers. I first removed the EGR valve motor assembly. None of these parts will be reused 
(http://i.imgur.com/EayUPhk.jpg)
(http://i.imgur.com/4btiiVV.jpg)

That didn't help, and upon further examination, I could see that removing that front cooler was going to be pretty difficult, so for the second time I called Holton at Alligator. He clued me in to the fact that the V-band clamp needed to be loosened all the way, which I did. After having done that, and removing the PCV valve from the inlet, the elbow came right out!
(http://i.imgur.com/E10qPYx.jpg)

Right about then the UPS guy showed up with a couple of boxes. I opened them to find these cool parts all oiled up and bubble wrapped inside. These parts are for the build up of that bump-fire M4 I am going to put together soon.
(http://i.imgur.com/dEnbxAq.jpg)

OK, back to the business at hand. Next I started removing everything connected to the downpipe, and the turbo heat shield as well.
I purchased a special double hinged ratchet and already had the O2 sensor socket which is shown here and makes removing our sensor a snap. THat O2 sensor will not be reused.
(http://i.imgur.com/NQgVoBI.jpg)
(http://i.imgur.com/aJIifj5.jpg)
(http://i.imgur.com/NhZGO8Q.jpg)
(http://i.imgur.com/lpPf0Bi.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 12:48:30 PM
Next the actual heat shield is removed
(http://i.imgur.com/jUarri7.jpg)
(http://i.imgur.com/5eFUwWj.jpg)

With the heat shield out of there the down pipe remaining sensor and V-band can be removed. I actually removed the down pipe with the heat shield still attached by persuading it downward with a length of steel pipe and a rubber mallet.
(http://i.imgur.com/A7hTboZ.jpg)
(http://i.imgur.com/R9yLlBq.jpg)

Back to the top side, I went after the rubber coolant lines, disconnecting and removing them as well.
(http://i.imgur.com/OVI7tYy.jpg)
(http://i.imgur.com/ZAHNeGA.jpg)
(http://i.imgur.com/jc63oXk.jpg)

More hose removal:
(http://i.imgur.com/E1fYW14.jpg)
(http://i.imgur.com/oKQr7vu.jpg)
(http://i.imgur.com/CNXgVvF.jpg)
(http://i.imgur.com/Hi90Qht.jpg)

I noticed that not very much dexi-cool anti freeze actually leaks when removing all this stuff so the mess is not too much to handle.
Here's a shot of the bed of the truck which is serving as temporary parts storage. It's filling up! Most of the rusty iron stuff will not be reused!
(http://i.imgur.com/MuC1d99.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 12:51:45 PM
                                                                                                                                             (2394)
The plan is to resume the EGR removal tomorrow morning. It will be the most difficult part of the whole delete procedure. Every bolt I have to go for can not be seen directly. Take a look at the two engine pics Holton sent me. When you're looking ath your engine that plastic hat is about a foot above the turbocharger. The turbo is also well aft of that hat with all of the exhaust part of it located well under the cowl and firewall...Yea, starting to get the picture?
So while doing the contortionist thing you will have to remove 8 bolts which are really on tight totally from feel. The only time you will ever be able to see them is when you finally get them out.
(http://i.imgur.com/n4Amj0p.jpg)
(http://i.imgur.com/dF98YFR.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 12:55:24 PM
First, thanks Ashley, sometimes that's all it takes!

OK, let's get on with day 2 of the EGR delete.
After 9 hours the first day and 8 fatiguing hard, hard hours the second I am still not done.
Unequivocally this is by far the hardest thing I have ever done on this truck. It rivals or surpasses almost anything memory can serve up. This delete is definately not for the timid. It is world class hard, period!

So knowing that I had to tackle those feel only bolts I started with removal of the remaining heat shield. There is one covering the EGR portion of the passenger up pipe and one over the turbo exhaust side.
(http://i.imgur.com/AMmVCY5.jpg)

I thought the best way to tackle the hard stuff was the hardest stuff first. In retrospect I still don't know which was the hardest, with each bolt removed feeling like a hard won victory. The up pipe has three bolts securing it to the back of the EGR cooler assembly. If you look carefully in the picture you can just barely see my ratchet buried way up inside the firewall. You can't see the botl head, you just have to find it by feel. I used a mirror to look at it first to give me a general idea where to hunt. You can only get one of the three from below
(http://i.imgur.com/k12W7DP.jpg)

Moving top side you now can loosen and remove the remaining two flange bolts. Next remove all of the EGR cooler mount bolts and the remaining rubber coolant lines. This precise tool helps with getting stuff out of the way!

When everything is disconnected a little movement can be had. The whole big heavy coolant filled L shaped cooler comes out as one unit.
(http://i.imgur.com/KTrFbUT.jpg)
(http://i.imgur.com/ULfVZAM.jpg)
(http://i.imgur.com/SMaJAMh.jpg)
(http://i.imgur.com/5w6GVPF.jpg)

Then all at once the truck lets out a sigh of relief and the massive thing is free. I remounted it semi permanently on the floor!
Along with the cooler assembly the aft mount comes out as well.
(http://i.imgur.com/sX3FWlU.jpg)
(http://i.imgur.com/qAnWx57.jpg)
(http://i.imgur.com/pkEBB7V.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 01:00:50 PM
Next you can finally tackle the up pipe. You will need an assortment of 12mm 12pt. wrenches plus a can of spinich. Those bolts are torqued to several million ft. pounds and will create a decent hernia if you don't have one already!
The old up pipe is a mess and gets in the way. I decided to saw off the upper extension to gain some room.
(http://i.imgur.com/Is1tzwJ.jpg)
(http://i.imgur.com/RVK8rOW.jpg)

After another hour of speaking your favorite french in which I became fluent all over again, you can finally drop that passenger up pipe onto the floor!
(http://i.imgur.com/Qo0y2Vu.jpg)
(http://i.imgur.com/bvk4Rgx.jpg)
(http://i.imgur.com/Kd9kSiB.jpg)

At this point the engine is getting a lot less cluttered. It's still cluttered, just not several layers on it like before.
(http://i.imgur.com/Hzj3lKG.jpg)

This the point where you finally start reassembly. I started with installing the new up pipe reusing the old stainless gaskets
(http://i.imgur.com/b20ZISz.jpg)

Next part going on is the new down pipe, an alligator diesel part supplied by my trusty friend, Holton. I'm sure he (Holton) is no with us at the moment, he surely passed out when reading the thread and coming to the part where I showed the hammer!
To install the down pipe, all you really need to do is push the firewall in about a half inch where the down pipe would contact it. This will ease installation. Installing it with all the junk out of the way is not that difficult.
(http://i.imgur.com/HdD17aO.jpg)
(http://i.imgur.com/eLhYd5g.jpg)
(http://i.imgur.com/T11N25V.jpg)
(http://i.imgur.com/hU3YLbx.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 01:06:57 PM
Next I tackled the first of two water lines. The firewall connection is now connected to a coolant pipe coming up from the engine block right beside the turbo. Taking the supplied "L" pipe which has two different diameters, I trimmed it to fit, silicone sprayed the nipples and slid it home and clamped it tightly.
(http://i.imgur.com/O0FWd8f.jpg)
(http://i.imgur.com/PxSZH4B.jpg)
(http://i.imgur.com/4rmsVhP.jpg)
(http://i.imgur.com/4R6IpNM.jpg)
(http://i.imgur.com/fLUuOLN.jpg)

Next the front to passenger side smaller diameter but longer hose was fastened in place
(http://i.imgur.com/XLghwfT.jpg)
(http://i.imgur.com/CfREREA.jpg)
(http://i.imgur.com/pRUab2X.jpg)

I removed the unused 9th injector nozzle and supply line from near where the hard line attaches to the actual injector which sits on the valve cover in a cradle. I want to get rid of the injector as well, but for now this is as far as I am going for now
(http://i.imgur.com/c0AL3dt.jpg)

This is what the engine bay looks like at the moment, along with all the parts removed that will not be reused, and the truck sitting helplessly in the garage for another night.
(http://i.imgur.com/DXteCyp.jpg)
(http://i.imgur.com/PCMVwo5.jpg)
(http://i.imgur.com/3yhsn8w.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 01:32:59 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 01:37:40 PM
I finished the EGR delete today
I picked up where I left off yesterday first finishing tieing off the water bypass hoses and properly securing them to prevent chaffing.

With that complete it was time to install the Alligator Diesel block off plate that Holton supplied which is an easy task with everything out of the way.
(http://i.imgur.com/dMKbxf6.jpg)
(http://i.imgur.com/jQzhTvC.jpg)
(http://i.imgur.com/DHT5fXv.jpg)
(http://i.imgur.com/u0XM4eV.jpg)

Reusing the old gaskets and bolts, it is a simple install taking only a couple minutes.
That plate measured .260" in thickness so we're looking at 1/4" plate steel nicely powder coated.
For some reason the plate looks black in the photo, but it is silver spotted over black, a unique finish to say the least.
(http://i.imgur.com/IjLnrRE.jpg)
(http://i.imgur.com/Vv0Js5K.jpg)

Next the turbo intake elbow goes on
(http://i.imgur.com/j9nWekK.jpg)

Then the silver "S" pipe
...and everything else.
I refilled the approximately 1.5 quarts of Dexi-cool radiator fluid, checked everything and fired it up
To get the small bolt into the mount under the butterfly valve I came up with this technique. That's one of the bolts you can't really see. This technique worked just fine
(http://i.imgur.com/HSJjvIh.jpg)
(http://i.imgur.com/URcrBQg.jpg)
(http://i.imgur.com/GhszK7T.jpg)
(http://i.imgur.com/unqxYSx.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 01:39:28 PM
                                                                                                                  (2441)
Quote:
Originally Posted by f*********
"Suggestion for the next mod: 3" driver's side intercooler pipe."


OK, fine!

Actually, Holton talked me out of it for the moment.
Next is the Rare parts tie rods and the Cognito upper control arms.
Right after that is the Amp Research steps.
As I explained earlier, I plan to "Up-Armor" the Amp steps so they can take a real beating.
Then I am installing a hypertech inline speedo calibrator
You see, I already ordered all that stuff and I have tracking numbers on it.

On that intercooler pipe, I have plans to install twins, so we are sort of waiting until they come out to see if that pipe will still work. I assume it will, but who knows???
I am also short final to getting the new Road Armor rear bumper. They have already built it and should be shipping it to me pretty soon. That will be an awesome addition.
Later when it gets cold, I will be fabbing up a rear tire carrier to weld to that beautiful bumper. I just don't want to do any heavy duty fab work while it's still warm.
Anyway that is the current lineup...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 09, 2014, 07:23:49 PM
I have my first post EGR delete drive impressions
First, the truck sounds healthy and runs great. I'm sure a lot of it is psychological and not actual, but I T H I N K the engine runs mo-better. That's a highly technical term, please don't ask me to elaborate!

Secondly the mileage has increased a solid 1 mpg!!!!! That's a 5% increase in economy. Before I did the delete, I was always averaging 18.9-19.0 on a given loop. Today with all things being equal except that the temp is about 10-12 degrees cooler, the mileage indicated 20.0! That was for 70% highway, 20% in town and 10% rural. I was running the air conditioner and driving at 70-75 mph actual.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 10:52:20 PM
Save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 10:57:41 PM
OK back to the build, at least for awhile
Just got the next batch of parts in.
Here are the Rare Parts Heavy duty tie rod assemblies
and
The Cognito upper control arms with a ball joint
(http://i.imgur.com/p7jXlkm.jpg)
(http://i.imgur.com/PEKB6I6.jpg)
(http://i.imgur.com/voJmgGQ.jpg)

Next is the gear oil for the rear axle and an oil sample kit I picked up from Willie (MrManners)
(http://i.imgur.com/4QH1If1.jpg)
(http://i.imgur.com/5EmTetm.jpg)
(http://i.imgur.com/0ijovQc.jpg)

There are a couple more parts as well, including the hypertech speedo calibrator and a cool billet set of sway bar end links.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 11:00:35 PM
I wanted to share this private conversation where Ashley asked a question whose answer would be of benefit to all:

Originally Posted by Armalite
"Don, what's the reasoning behind the cognito uca's? I know what you're trying to accomplish in the front end, so I'm assuming this is a needed part to get to that final point? Just curious why you already have the lift, but now you're swapping uca's out to cognito? Ready to see it all take place".


Well, as I dive deeper into this project the weaknesses of the design (few as they are) are showing up, all in view of what I want to do. So imagine you are being chased by some enraged people and you decide to leave the highway at say 70 mph. You will need significantly more suspension travel to accommodate. The stock truck like most gives us what 5"-6" travel. The limiting factors are exceedence of critical ball joint angles, tie rod angles, CV joint, and then finally with shock travel and bottoming out on a bump stop.
I plan to address each one of these issues and to do something never before done. In addition to everything I want to invent a disconnecting sway bar like the Dodge power wagon has.
So I have a lot more shock travel, enough to max out the ball joint, which is next. The cognito arms will immediately correct for this and even allow me a tad bit more caster. That's why the cognitos and the rare parts tie rods are going on next. When it is all done it will look alot like stock, but should perform about 100% better.
If you don't mind, I'm going to post my response in my thread to share with everyone, cool?


Quote:
Originally Posted by D*********
"Did you go with the ball joint or uniball UCA?"



Knucklehead !

From a few posts ago:

OK back to the build, at least for awhile
Just got the next batch of parts in.
Here are the Rare Parts Heavy duty tie rod assemblies
and
The Cognito upper control arms with a ball joint


Sorry, couldn't resist...Say how did you do with reading comprehension? Man, sorry again, I'm just beating you all about the head and shoulders...
My bad, I'm a terrible guy!

OK, enough coffee induced fun (CIF) I went with the ball joints on purpose. I have A LOT of experience with uniballs, rod ends and the like over a few decades in whirly birds. That's how all that really fast moving junk over my head is held in place. Obviously I have put all of that stuff through it's paces in all sorts of the same environment as our trucks see. Dirt?? Dust landings! Salt? Hovering over the ocean at low altitude and sometimes actually landing in salt water! Sticks, debris and so forth: Landing in the woods, 7.62mm bullets: Oh, sorry we don't have that here yet!
Anyway with all that stuff and my experience I have to say exposed spherical balls and races don't always do well in those environments. Don't care you can carve the ball out of refried stellar matter plated with kryptonite (No such real stuff guys, so stay with me) and it will wear. But for some reason you slap on a generous coat of grease and nothing gets to it! Heck you can hoist up a cannon from the ocean depths that has rested there for a few centuries and if it has a coat of grease on it, you can dry the thing out, load up powder and ball and take on the Haitian navy. OK, maybe that's a stretch, the Haitians don't have a navy, but you get the idea.
Nosir, I am using the good old non-sexy spong-bob-square-pants ball joint!
Good thing I was able to give you a short answer!!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 11:05:02 PM
Today, I installed the Hypertech speedometer inline calibration unit.
There has always been a question as to whether this unit is compatible with H&S tuning. When I called to discuss it with the H&S folks, mum was the word. Nobody knew anything.
Left out in the cold as we who have different tire sizes are with the H&S inability to calibrate for the change we have had to contend with an inaccurate speedo.
Well, I am happy to report we no longer have a problem! The Hypertech unit works seamlessly with the H&S tuner!
It is a simple install which I will detail in the next few posts.
First you install the CD into your computer, attach the module with the USB to micro usb cable and do the calibration. I calibrated my speedometer for both tire size change and a gear change.
Later testing showed accuracy in the plus to minus 1 mph range. That's plenty good enough to consider accurate. I tested the speedo reading to my GPS speed and found all speeds to be within 1 to 1.5 mph from creeping along up to 80 mph!
Here's what comes in the box, plus the CD:
(http://i.imgur.com/HOSlHnT.jpg)

Begin by removing the left and right trom pieces. They pop out carefully (Ashley) using a broad blade pry bar.
(http://i.imgur.com/T7OShkd.jpg)
(http://i.imgur.com/W25DQVV.jpg)
(http://i.imgur.com/VHBZPum.jpg)
(http://i.imgur.com/dE99jxz.jpg)

Pry very carefully! (Ashley)
(http://i.imgur.com/mP5wYer.jpg)

Next remove the 4 screws holding in the cluster trim piece and remove it
(http://i.imgur.com/mP5wYer.jpg)
(http://i.imgur.com/u27y7Z0.jpg)
(http://i.imgur.com/bxdrI9G.jpg)
(http://i.imgur.com/FudEdwX.jpg)
(http://i.imgur.com/uzm0STU.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 11:22:58 PM
Unsnap the steering column top trim piece and remove it. unbolt the cluster topside screws then start to gently (Ashley) pull out the bezel trim piece.
(http://i.imgur.com/7dLh8YL.jpg)
(http://i.imgur.com/Sz7Z5w9.jpg)
(http://i.imgur.com/i3vi1OU.jpg)
(http://i.imgur.com/K8zkLix.jpg)

Remove the remaining two lower screws and wiggle out the instrument cluster. On the back is a single multi wire attachment. Unplug that and the instrument cluster will be free.
(http://i.imgur.com/1v6NJKU.jpg)
(http://i.imgur.com/FnxJDfH.jpg)
(http://i.imgur.com/8NNBpqH.jpg)
(http://i.imgur.com/3pOZyWc.jpg)

Installing the module is a snap (literally) just plugs together and reassembly begins
(http://i.imgur.com/jJllGyh.jpg)
(http://i.imgur.com/xHLxtvm.jpg)
(http://i.imgur.com/JjR64Hd.jpg)

I tidied things up and reassembled the cluster and reinstalled the trim pieces .
(http://i.imgur.com/iZWMeGB.jpg)
(http://i.imgur.com/8L8eBSh.jpg)
(http://i.imgur.com/qUY8kSW.jpg)
(http://i.imgur.com/6CmesHm.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 11:25:34 PM
I test drove the truck for about 30 minutes. The speedometer was almost dead on and not so much as a check engine light. The various pictures show the closeness of the GPS speed with the speedo speed.
This is a great mod. I owe Holton at Alligator a debt of gratitude for making this possible. He supplies me the parts at great prices and is always calling to check up on the install and following up. Just today, he called again to check if I was happy with the EGR delete mod, which I am overjoyed with.
This truck is just running great now!
(http://i.imgur.com/7VV9lM0.jpg)
(http://i.imgur.com/YSWLXqb.jpg)
(http://i.imgur.com/QGULJkU.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 11:28:26 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 11:31:03 PM
All right boys and girls, off to another modification. Today I will be installing the Cognito upper control arms (UCA) and start to install the Rare parts tie rods. Once you get into the writeup, you'll see why I just started and am not finished yet.

So first we begin by removing the wheels, placing the beast on sturdy jack stands and pulling off the factory arms.
(http://i.imgur.com/OaQi91y.jpg)
(http://i.imgur.com/Eassb7E.jpg)
(http://i.imgur.com/XIOa87X.jpg)

Removal is straight forward and the loss of blood vs actual work acomplished ratio is pretty good, actually excellent, rivalling a great shave with a new razor blade!

The factory arms are no match for the mighty Cognito parts!
(http://i.imgur.com/CbHNZaA.jpg)
(http://i.imgur.com/lzWLw3G.jpg)
(http://i.imgur.com/SKXkPLt.jpg)
(http://i.imgur.com/vRq9qRV.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 10, 2014, 11:42:18 PM
                                                                                                                    (2560)
You need to assemble the Cognito arm bushings and ball joint before it is ready to install. I used WD-40 and a rubber mallet to install the first half of the poly bushing, then my handy vise as a make-shift press to push in the other half.
(http://i.imgur.com/eehTDUN.jpg)
(http://i.imgur.com/Jbn59vu.jpg)
(http://i.imgur.com/vuiQqo2.jpg)
(http://i.imgur.com/9vkZ8Ee.jpg)

And still more straight forward assembly, all very easy.
I gave all exposed metal parts and bolts a coat of EastWood "Shark Hide" to protect against corrosion.
(http://i.imgur.com/Hp3w3QI.jpg)
(http://i.imgur.com/zFTMhw1.jpg)
(http://i.imgur.com/ozKCSbr.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 08:41:11 PM
Paying attention to the details, I prelubed everything with lithium grease and wiggled the new arm into place. First I tapped the bushing slots a bit with a hammer to gently spread them a tiny bit to make the arms easier to slide in. It worked, as they went in with just enough resistance.
(http://i.imgur.com/0r3sIXB.jpg)
(http://i.imgur.com/ldE6Vfh.jpg)
(http://i.imgur.com/cGKFhSz.jpg)


Same with the other side. It, too, was an easy install. You only need to pay attention to details to make this a clean easy install.
(http://i.imgur.com/MWwtw7m.jpg)
(http://i.imgur.com/uIfKHVK.jpg)
(http://i.imgur.com/exOo6Mq.jpg)

I only snugged the bushing bolts slightly to allow them to turn in their mounts on the drive over to the alignment shop. THat way when the tech tightens everything up after settling has taken place, the bushings should be in a "neutral" position and able to flex more freely in both directions.
So, other than the alignment, that's it folks, I'm cognitoed up!
In the photos notice how flat the ball joint is at ride height, just perfect. I also noted the control arm has extra clearance from contacting that bothersome upper travel limiter that is responsible for horible rides on torsion bar cranked lifts (bad idea!)
(http://i.imgur.com/izPsQ0l.jpg)
(http://i.imgur.com/eW5aqD5.jpg)
(http://i.imgur.com/TXnn0ti.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 08:44:39 PM
Next we are going to get into the new Rare Parts tie rods. The news is going to be mixed for me at least, and I discovered a problem that no one a=over at Rare Parts or Holton, for that matter could have forseen.
Note: PAY ATTENTION: These replacement tie rods are designed to replace stock tie rod assemblies. They may or possibly may not fit a non stock, lifted application. I discovered that they will not fit the Fabtech spindle, at least not yet, but I have a plan!
I started by pulling off the stocker then did a good side by side. See any differences?
(http://i.imgur.com/4H7Wor0.jpg)
(http://i.imgur.com/RsjLxVJ.jpg)
(http://i.imgur.com/Wf3pAqF.jpg)
(http://i.imgur.com/ZaiWalj.jpg)

If you answered that the Rare parts tie rod assembly is much beefier, you would be correct. Stock is .690" in diameter, where as the Rare parts is a full 1". Yep, thats .310 more diameter to yank on before impending doom.

If you also answered that the Rare parts is too long, again, you would be correct! Now here is where it gets confusing. I had previously removed 3/8" from the factory tie rod IAW Fabtech's installation instructions. Measuring it all out the Rare Parts tie rod was exactly 1" too long. If you subtract the 3/8" from the total length, the rare parts tie rod would still be 5/8" too long.

That is pretty easy to fix, simply cut 1" off of both the sleeve and the stud end of the tie rod and bolt it in like it never happened. That's what I decided to do.
(http://i.imgur.com/LN7lfZn.jpg)
(http://i.imgur.com/8SolAuH.jpg)
(http://i.imgur.com/tCKanVl.jpg)
(http://i.imgur.com/hRW4anT.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 08:46:10 PM
At this point I bolted the two halves back together and reinstalled the new tie rod assembly into the truck. That's when I discovered the next issue. The fabtech spindle came with a new tie rod end and the size of the fabtech tapered stud was larger than the stock LML. Therefore when I dropped in the Rare Parts tie rod into the spindle it all but fell through. It was way too small diameter. In fact I measured the small end of the rare parts taper at .590"
THe small end of the fabtech tapered hole measured .680"
That makes the hole about a tenth of an inch too big.

At this point I called Glen at Rare Parts and discussed the problem I was having. The taper size has nothing to do with them, and is attributed only to the fact that Fabtech decided to use bigger, stronger tie rods than even the factory larger LML parts. We were both miffed (confused) by the length issue. He measured his tie rod at about 15". I measured my modified assembly at 13 9/16". So his probably does fit stockers but will require modification to fit with fabtech lifts and maybe others as well??
Glen was a real stand up guy. We figured out that we needed a tapered spacer bushing. During an earlier call with Holton, we both came to the same conclusion. Anyway, Glen is going to machine me up a set to drop in the fabtech spindle so I can continue with installing his excellent tie rod assemblies.
SO this not done, more to come. I decided to make one more adjustment to the tie rods before throwing in the towell tonight:
(http://i.imgur.com/hIvYLWg.jpg)

I ran out of time but intended to install these excellent sway bar end links to replace the flimsly stockers. There cool parts actually have a swivel ball on one end to allow for flexing without binding. How cool is that!
(http://i.imgur.com/wMUF3pe.jpg)
(http://i.imgur.com/skJMoK2.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 08:47:03 PM
Resting back on the ground, here's what it looks like prior to alignment:

Also, I took some measurments of the suspension to see how much movement I am getting. Bottom line is NOT MUCH!
Sitting on the ground the shock shows 3.5" extension. Jacking up on the frame until the wheel hangs freely, the shock extends to 5" (Pathetic!! 1.5" droop!)
I then jacked the truck up under the lower control arm until the tire was 6" off the ground. I measured the shock to have exactly the same 3.5" of shaft exposed! W H A T???? No up travel? Now I know when you load it up with say, hitting a bump, you are going to get some more travel, but so far I would rate this stiff suspension as a third a point less than awful!
I started looking for bind points and several were immediately noticeable. First the stock UCA bushings are super stiff and flex ver little. I had to really force the stock UCA to move at all even when disconnected from the spindle. When I loosened up the bushing bolts, it freed right up! So the Cognito UCA will fix that.
The stocker is limited down big time by that droop stop protrusion from the frame. At some future point mine will have a date with a saw!
It seems the sway bar is really holding things up as well, so that is going to get some attention. NExt the tie rods don't have all that much more down travel before the angle maxes out. I'm going after the lower bump stops tomorrow, removing about an inch from them.
Hold it, I hear something from the garage...It's a voice... "free at last, free at last, free at last!
(http://i.imgur.com/rwOGVfT.jpg)
(http://i.imgur.com/wcho39P.jpg)
(http://i.imgur.com/71UPBJP.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 08:49:25 PM
Ordered these tonight from Rick over at ProFab performance.
I believe Holton has actually bolted a set of these manifolds onto an LML truck, but talking to Rick, he has not. So other than the Alligator guys, I will be the next to bolt this setup onto a LML truck. I plan to have them coated along with the up pipes, so it will get even prettier under the hood than before!
(http://i.imgur.com/thH6T54.jpg)
(http://i.imgur.com/Ci2qKG1.jpg)
(http://i.imgur.com/1hRSyRE.jpg)
(http://i.imgur.com/HhPqk57.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 08:54:13 PM
Today I also added 50 horsepower to my survival rig set up. I didn't actually add any horsepower to my duramax, but to the thing that could be on the trailer behind it!
Purchased a John Deere 825 Gator in olive drab and black. No shine on it at all. I ordered the fox off road shocks, the high performance exhaust and all the armor they sell. I also outfitted it with all their lights, aluminum (black) wheels, and a couple other things.
I have owned a gator for quite awhile. I also own a 850D diesel gator that will run on anything, goes like a banschee cross country and will start and run on liquid chicken grease. I don't know if I'll keep the diesel, but right now I'm thinking of keeping them both, and making the 825 a tactical scout vehicle for quickie runs to town across varying cross country routes.
(http://i.imgur.com/xv2riXu.jpg)
(http://i.imgur.com/qqiOq9i.jpg)
(http://i.imgur.com/TZQCIff.jpg)
(http://i.imgur.com/1NVzCxP.jpg)


Quote:
Originally Posted by FC5452

"...... did that bullet help those tie rod ends any?"

 

Couldn't bring myself to actually pull the trigger. Last time I did that sort of thing it cost me a computer (for real!)
(http://i.imgur.com/JOjK4mt.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 08:58:39 PM
Quote:
Originally Posted by Armalite
"Those gators are nice! Spent some time on one up in Illinois. Loved it ! Good purchase...


You going to let us in on what you will coat the manifolds with? "

Talking with Rick last night he had several products, or perhaps it was colors available.
In the past I always sent my headers to Jet-Hott Coatings to get them inside and outside flow coated. That process would aid the Duramax in two significant ways. First it does not transfer heat to the surrounding air aw well, meaning it keeps the engine bay a tad bit cooler. That could possibly account for less hear soaking of air inlet devices such as aluminum pipe, air bridge, and so forth. Secondly it then transfers more of that heat (energy) to the turbine blades possibly generating more force to turn the compressor. It also smooth's the interior metal surface somewhat by filling microscopic low spots. If you understand parasitic drag, that fact alone would speak volumes to you. Basically, the gasses passing over a smoother surface, do so with less friction creating more of a laminar flow. Graduate stuff there, sorry, but it's technical.
In terms I understand, coat the manifolds and the Powerstroke goes away out fo view in the rear view mirror mo-quicklier!

So, what I asked Rick to do was to do the manifolds in a bright silver and the up pipes in a titanium color. Why pretty silver you ask? Because if the manifolds ever develop a crack, the black sooty junk will show up very well on that silver backdrop! Why the titanium? No reason, I just liked the way Ti-Tane-e-um sounds!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:10:10 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:16:41 PM
Did an install today, well, almost did one. I am installing a Kenwood GPS/cd/dvd/sirrus XM/tuner in the stock radio location. It's quite complicated and the instructions aren't all that clear. I also purchased an adapter to make all the factory stuff work, but as of 2200 tonight I still couldn't squeeze the thing in there and so far, no XM !
Will post it up tomorrow if I don't shoot it with that mossberg first!


Quote:
Originally Posted by mrmanners
"I did a similar setup on my wife's LBZ when we bought it. Fought with that thing nearly all day before I got it all to fit in the dash. Said many a bad word that day! Probably won't do another one. Too much of a pain even with the harnesses Crutchfield sells."


I'm with you exactly. I purchased it all from Crutchfield thinking it was a simple plug and play...errr...no...not so simple.
The problem is that the instructions are not clear at all. No where in those "Clear and helpful" instructions did it ever say you would not be using several of the supplied harnesses, and that only one actually worked. (Apparently they give you extra ones to drive up the price with obsolete equipment) So when it told me to start attaching the 22 pin harness I happily did so. Later when I noticed there was another 22 pin harness, I thought about the peanut butter rule. If you butter a slice of bread with peanut butter and then drop it, which side hits the floor? Yea, I know it's supposed to be a 50/50 probability. But we all know the sticky side hits the floor first, like as in always!
Same-same with the wiring harnesses. If two are identical and you select one to install, it will be the wrong one, but you will only discover that fact after it is all assembled (soldered together!)
Well, I try to find the positive and the good in everything, so from yesterday and last night I will say, I got a lot of practice soldering, stripping wires, and using shrink tubing, and it turned out better the second time I did it! I missed supper though, but what the hay, I'm a tad over fighting weight anyway, so that's all good, I guess?!
Then there is the problem with physics. There is one basic law that is giving me a fit at the moment, but when I figure out how to change that law, I'm in there. That would be the property concerning physical matter that says something about two pieces of matter can not occupy the same space at the same time. Hog wash! If that was true then none of these aftermarket radios with their attendant two miles of harness wires would ever fit, so right there is proof positive that that particular law is in error. And if that one is wrong, how many others are corrupted as well? I think I'm on to something here! Anyone who has read my book, there is a chapter where I discuss aerodynamics. I prove beyond some doubt that, that is all a bunch of bunk as well. Ever see a F-4 phantom fly? Nuff said, aerodynamics does not exist, it's all just power and some other undefined stuff! So I'll be back to the laboratory (garage) again in a few to start, well, continue, my efforts to disprove the laws of physics that this drunkard day dreaming hippie from hundreds of years ago, Isaac Newton, came up with one day while in a semi-conscious state of mind!

Quote:
Originally Posted by KensAuto
"do you have to call xm to register the new setup? I would also like to install a fancy setup in near future. kinda tired of working on the outside of the truck "

If this thing refuses to fit after a few more hours of pain and frustration, call me and I'll give it to you.
Of course, you'll have to deal with the extra 9 mounting holes I'll install in it with the mossberg, but you strike me as a smart guy, you'll figure it out!

(OO buckshot has 9 pellets per shot)

Quote:
Originally Posted by STLASER
"You know I've been thinking about this thread and noticed a problem. My theory is that you could have had the same truck for half the money if you wouldn't have a bought a running truck in the first place.  Because when your done their literally will not be anything left of the original truck anyhow". 

Stock's not good...
I'm only trying to fix it!

Quote:
Originally Posted by KensAuto
"just try and miss the screen with those pellets!"

Believe it or not the thing is still not in! I cut the bow string off a compound bow and tied that to the harness which I then fished through the glove box and pulled on that while pushing back on the radio. I think some ejection seat parachutes are packed that tightly, well maybe not as tight as this radio will be. Heck if those screws ever let go, it will be like a 105mm coming out of that hole in the dash.
I had to walk away from it. Got on the new tractor and tore up stuff for awhile. It only cost me two maple trees this time! I'm going back out there in a moment. I unloaded the guns just in case it doesn't fit again.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:20:21 PM
Over the next few posts, I detail the installation of an aftermarket combo in dash GPS, tuner, DVD/Cd player with MP3 capability and expanded data storage.
I selected the Kenwood 5190 head unit which has all the above capabilities. Additionally, with a specialized wiring harness, which costs extra, you can retain all the factory capilities.
I selected Crutchfield this time because I used them in the past, and always with good luck.
Here's what I got:
(http://i.imgur.com/OAXimjJ.jpg)
(http://i.imgur.com/2OXjnpN.jpg)
(http://i.imgur.com/f7Ehozr.jpg)

First using a large flat pry bar, gently (Ashley!) pry out the trim bezel starting at the bottom and working up and around. It comes off easily if you're gentle (Ashley!)
(http://i.imgur.com/bPS3XN1.jpg)
(http://i.imgur.com/wJf01T0.jpg)
(http://i.imgur.com/wTPSi5m.jpg)
(http://i.imgur.com/9c7faod.jpg)

Pull out the 8-7mm screws and the radio, temp control, and accessory panels can be pulled out.
Then the radio simply unplugs
(http://i.imgur.com/dZmNguu.jpg)
(http://i.imgur.com/IajzB9Q.jpg)
(http://i.imgur.com/whN2Hlt.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:25:14 PM
The kenwood radio has a remote USB plug which I later ran into the open part of the console. I figure I'll coil it inside a cup holder and pull it out when I want to hook up to a lap top or thumb drive. I believe I can update the GPS which is a Garmin using this port.
(http://i.imgur.com/uYu3Eu7.jpg)
(http://i.imgur.com/P86PsKk.jpg)

Some advise here: Pay attention to which harness you are using or you will get a lot of practice like I did before you finally solder on the correct one.
In my opinion, that adapter harness Crutchfield supplied is a mess. Actually it's a nightmare. It has so many wires, you could easily make a mistake. It has so many wires that it takes up more physical space than the truck actually has to offer, so something has to give if you are to fit this monstrosity.
(http://i.imgur.com/W0rFdsG.jpg)
(http://i.imgur.com/jjW7Fxh.jpg)

This project was truely no fun and I do not recommend doing it. To properly fit the radio, at least the Kenwood woth the required harness, you will need to cut access areas into the plastic liner the radios sit in. There is simply no way everything fits. I had to get creative when installing the new radio. I stuffed wires into every opening in that avionics bay. I even had to tie a cord to the harness, route that around the back of the dash, down through a labyrinth of cables, hoses, this and that. The purpose was to be able to pull on the cable harness while carefully working the Kenwood unit to it's mounting position. I worked a day and a half getting this radio in and finally only met with success after deciding to cut the plastic panels.
(http://i.imgur.com/ktfj6Ma.jpg)

But as with anything you really work at long enough, the radio finally yielded, I sacrificed enough skin and blood, and the stuff found a new home.
(http://i.imgur.com/HWas9MS.jpg)
(http://i.imgur.com/x4Sr9Zr.jpg)
(http://i.imgur.com/OXAfHZb.jpg)

Here's the plastic pieces I had to sacrifice at the alter of ill fitting parts to be able to move forward
(http://i.imgur.com/gb2014W.jpg)

Before / After:
(http://i.imgur.com/QFtUUza.jpg)

(http://i.imgur.com/6N0bASc.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:29:06 PM
Here's todays addition to the stable. The tractor is a John Deere 2720, 31 HP MFWD work horse...fits with the whole self sufficiency scheme. Not much in the way of electronics, but regretfully, some...

Next is the as delivered 825I gator, civil recon vehicle.
It's got a few goodies now but has a ton of stuff on order and coming in.
It will soon get:
Windshield, glass, with a wiper
Side body armor
Wrap around rear body armor
CV steel guards on all 4 lower control arms
Fox racing adjustable coil-overs
High performance exhaust
Hella mid range lighting
Somebody's long range spots
Roof mounted close in lighting
Tail light and turn signal kit
Winch

Then I plan to weaken the clutch spring and remove the speed sensor, which will allow for a 50+ top end
Add a power commander module +10%HP
Bolt on pioneer equipment
Bolt on fuel can(s) rack
Rifle mount
Tool kit and spare parts
(http://i.imgur.com/qVoEvM7.jpg)
(http://i.imgur.com/SsErbjN.jpg)
(http://i.imgur.com/I92WNwW.jpg)
(http://i.imgur.com/HK1Bm4j.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:33:26 PM
And on another topic. Guys I do like these Duramax diesels. So much so that you can see the evidence here on these hundreds of pages.
However, one EMP spike and that truck is an expensive parts bin or planter.
Because of that I am going to develop a backup vehicle. That truck will not be a D-Max, since they all have electronics. Nor will it be a crappy 6.2 or 6.5 GMC diesel.
It will be a diesel in the form of a 94-98 Dodge 3500 dually, Cummins manual trans truck. I do want a good spare that will run on chicken grease and start after a tac-nuke detonation or a good solar flare. I also have a diesel gator, 850D which is a reliable slower version of the much quicker 825I I just added to the collection.
ANyway, just throwing that out there, so when you see another build thread on a purist survivalist Cummins you won't get light headed and pass out.
OK, you've been warned.
Shawn, I can always plug that into that windmill/water pump thing you are building!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:35:45 PM
Boys and girls it's CPT again (Cool Parts Time!)
Look what just showed at my house fresh out of the ovens at ProFab Performance, compliments of Rick who makes all this koul stuff!
(http://i.imgur.com/nEJiENS.jpg)
(http://i.imgur.com/H6PJNxe.jpg)
(http://i.imgur.com/s5FofiF.jpg)
(http://i.imgur.com/MHfTPsG.jpg)

Yepper, those would be a set of his cast performance manifolds and up pipes.
I wanted to show off some of his work there, so I asked Rick to coat the manifolds in silver and the up pipes in titanium. Silver because it will show cracks better, and titanium because I like it. Since I paid for them I guess I got to pick.
(http://i.imgur.com/nLlRwIY.jpg)
(http://i.imgur.com/sGwP8w0.jpg)
(http://i.imgur.com/bXfw1cb.jpg)
(http://i.imgur.com/Uvo7quc.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:38:59 PM
Quality is right up there in the "as good as it gets" category, I found no casting flash, misaligned anything, nasty welds, and so forth. It seemed all welded joints had nice smooth inner transitions and it would appear that these things should flow like gang busters
(http://i.imgur.com/CuznBB7.jpg)
(http://i.imgur.com/w935ZNz.jpg)
(http://i.imgur.com/kjxbyIk.jpg)
(http://i.imgur.com/tyhR6wo.jpg)

He also supplies a good looking set of socket head stainless screws to thread those pretty manifolds into the D-Max cylinder heads!
(http://i.imgur.com/n3IWco7.jpg)
(http://i.imgur.com/mTWCOpQ.jpg)
(http://i.imgur.com/7rQjxCa.jpg)

It's difficult to tell from the poor photos, however each port is angled backward to nicely blend into the high velocity gasses. The factory manifold has awful right angles that is no doubt causing a lot of turbulence (poor flow). I would imagine these manifolds should provide better laminar flow, less turbulence which should allow the heat to pass along (Lower EGT's) to the turbine. THat extra heat will provide more "UMPH" to the turbine which will undoubtly make more power. That's a triple threat performance gainer and when it's buttoned up, ou won't even be able to see them ;-((
(http://i.imgur.com/qVAxz8f.jpg)
(http://i.imgur.com/R0Z5zrM.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:43:45 PM
Change of venue
Let's get back to building
Today was a really easy project
Replacing the stock sway bar end links with a quality set of RCD suspension units.
These things are much beefier and feature a ball joint in one end to cope with the minor misalignment present in all suspensions. THat should eliminate a possible bind point and make them almost break proof!
I broke some on my Hummer once!
Here's what comes in the box:
(http://i.imgur.com/ypV3V23.jpg)

Two bolts and the stockers come right off. I recommend loosening the sway bar mount bolts as well
Here's the stock stuff and the RCD parts
(http://i.imgur.com/aXGFDOU.jpg)
(http://i.imgur.com/QkVs2If.jpg)

Here's some of the hardware stack up
(http://i.imgur.com/GIVyrlD.jpg)

And the units reinstalled:
(http://i.imgur.com/g8SvQUz.jpg)
(http://i.imgur.com/ylSiqpO.jpg)
(http://i.imgur.com/vPWnUA2.jpg)
(http://i.imgur.com/1FxyUQl.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:51:20 PM
Quote:
Originally Posted by flyin6
"Those tabs are fabtech parts.
I'm not done with this setup. I don't like the extensions. Basically they are reducing the effectiveness of the factory bar. I plan to do something with the bar itself and about then I think I'll can those tabs and redrill or weld in new tabs "


Posted by Armalite:
I know you're not even close to revealing your final product ! Those tabs just threw me off. Didnt look like something you would put on your truck, unless it came with the kit, and was the only way to make it work at the time. Wont be long and you'll have it back and better then before.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 09:51:37 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 10:07:18 PM
.......OK, A couple predesone and about 8 hours and the swelling is still here (big time) however the pain abated.
So
I built that up pipe.
I'm going to post up how to do it if anyone wishes to do theirs as well. The one you see getting fabbed up here is free to the gentleman who I identified as needing it the most.
If you recall, I had taken a saw to the "Y" portion of the passenger pipe just to gain some working room. That's why it looks cut already. But this gives you an idea of what you will be working with.
(http://i.imgur.com/EU2N7V8.jpg)
(http://i.imgur.com/a6m0Cnm.jpg)
(http://i.imgur.com/pA9BZrp.jpg)
(http://i.imgur.com/W0GmCav.jpg)
(http://i.imgur.com/lJyHAob.jpg)
(http://i.imgur.com/sqgNg5k.jpg)
(http://i.imgur.com/mxWBJph.jpg)
(http://i.imgur.com/Be3AEaT.jpg)
(http://i.imgur.com/93jlVqi.jpg)
(http://i.imgur.com/27Ani3m.jpg)
(http://i.imgur.com/YkCapBK.jpg)
(http://i.imgur.com/djULjBO.jpg)
(http://i.imgur.com/pL8PtmE.jpg)
(http://i.imgur.com/BDj70rj.jpg)
(http://i.imgur.com/jwkS4rD.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 10:09:42 PM
Quote:
Originally Posted by flyin6
"Knowing this is stainless and will see short of 1700F I went over the corners with three quick drag passes to build up material to shed heat. I went over the other welds as well so what you see is actually two passes deep. I didn't try to make it pretty (obviously) but just pile on a lot of material to allow something to carry the heat.
So here is the pipe finished, wire brushed and ready to ship. Tony, if you want it, It's yours, will ship Monday. Just agree publically to do the same for the next guy and you are the new up pipe winner! "

Posted by FC5452:
For those that are following Don's thread, this is a testament to this mans personality. Between my personal life and my aspirations to make my own 600 hp duramax, I was we'll on my way to start. When an up pipe issue arose with the mfg with no expected turn around time for the distributor.
Don stepped up to the plate to do this for me, the intention was to be temporary in order for me to get the egr done and on the track by Oct 20th. When I got a permanent solution I would pass it on to the next guy, I agreed. When he finished I received the call the supplier, pipe is on the way. Therefore I do not need the one that he took the time to redo. For that Don I apologize openly here. It is only fair. As I stated you are a stand up individual, I don't know you from Adam, and you sure as hell didn't have to do this for me.
Long story short, Thank you.....
If there is anything I can do in return for your generosity please feel free to contact me.

Tony_P
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 10:25:25 PM
Quote:
Originally Posted by C****
"Don, any news you can share about the Road Armor rear bumper? I have been eagerly watching for it..."


Such a coincidence, I just got done looking at some pics of it that were just sent to me.
Here's the scoop on that. Road Armor moved to a larger facility and they are slowly gearing back up. THe bumper designer had to move, as in to a different state. He built the thing on paper, then finally got the parts laser cut and even tack welded together. THe bumper is not final welded or coated as of today, and the gentleman is having difficulty getting the welding gear fully installed and fired up.
He has sent me pics of the bumper several times now and I can say, I really like it. They promised the one that is tacked together at the moment to me and as we know that was supposed to happen months ago, however the difficulties have slid everything to the right substantially.
The pics I just looked at had it fitted to a 2008 1/2 ton silverado and it looks like it fits perfectly. It is winch capable, beefy as all get out and definately worth the wait.
THe engineer has asked me not to post the in process pics, so I have been closed hold with information. I don't know when it is coming, but IT IS COMING!


Quote:
Originally Posted by STLASER
"Have him ship it to me, we'll get it welded mo better!"


Ya know, if we sent it to you, it would be welded, plated in 1/2" battleship steel and reactive armor. Not saying any of that is bad of course, but you do over build stuff. I still believe when some archeologist digs up my truck in 3525 all they will find is a couple of gears held in place by that rear cover. Judging from the design of it, and assuming they figure the truck is of a utility nature, they will surmise that land mines must have existed everywhere along public highways in the early 21st century!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 11:00:15 PM
OK, the manifold install is finally underway. So far it's going well, making progress. Here's some shots of getting started:
(http://i.imgur.com/IBFxtIw.jpg)
(http://i.imgur.com/cFv5kzn.jpg)

Starting under the hood, I removed the turbo heat shield, then loosened the down pipe V-clamp, loosing the nut for all time in the 5th dimension...more on that later.
Then I removed the left and right well well liners
(http://i.imgur.com/izwGM7P.jpg)
(http://i.imgur.com/trMiqKb.jpg)
(http://i.imgur.com/VEVz0jr.jpg)

OK, supper complete, no one liked my pot roast ;-((
All right, forget that, on to the build. Since I had never had the driver's side wheel well liner out, and knowing the intercooler pipe had to come out, I started on that side with the removal of that spindly looking little straw!
(http://i.imgur.com/Kkr3wCl.jpg)
(http://i.imgur.com/J19tnOw.jpg)

The intercooler inlet is actually 3", where as the supply pipe is 2.5".
All of that is going to soon change, as I just happen to have an Alligator Performance Diesel 3" intercooler pipe sitting here at the ready. Here's a couple side by side shots of what was, and what is to come:
(http://i.imgur.com/fPtsrHa.jpg)
(http://i.imgur.com/otq9jpz.jpg)



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 11, 2014, 11:03:21 PM
                                                                                                           (3032)
This convoluted mess is looking worse than the Jersey shoreline! BTW, allow me to say that I feel sorry and troubled by the suffering that is taking place all over the north east at the moment. It is indeed unfortunate that so many have lost so much and our hearts reach out to you folks up there. But every day that passes is one more bring the recovery from Sandy a little closer.

This pic is looking through the jungle of Honduras during a mission I was on there, wait, sorry, was drifting there, it's actually the mess you will discover inside the wheel well on the drivers side and what you will have to wade through to be able get to the manifold!
(http://i.imgur.com/zPd4McP.jpg)

Next I pulled the down pipe out. Upon close inspection, I'd have to say I might have had some leaks judging from the carbon soot on the flange. I can't confirm it at the moment, but it looks like something might have been going on where the down pipe dumps into the exhaust pipe.
(http://i.imgur.com/DnVEGCL.jpg)
(http://i.imgur.com/r3dYT8K.jpg)
(http://i.imgur.com/SoVqeQb.jpg)
(http://i.imgur.com/mhJ29kQ.jpg)

I was able to loosen the passenger up pipe rather easily, compared to, say rebuilding the coliseum in a day. Saying that it was easier than the first time!
Once it was loose, I unbolted the passenger manifold heat shield and removed it.
(http://i.imgur.com/Dn5KhyR.jpg)
(http://i.imgur.com/gwbgrZ7.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 07:52:47 PM
Moving right along, next, off came the manifold
(http://i.imgur.com/dEenpX6.jpg)
(http://i.imgur.com/RuqmEY1.jpg)

The stock gaskets show no signs of leaking what so ever. I decided to reuse them.
(http://i.imgur.com/dMt8niG.jpg)
(http://i.imgur.com/49enVyI.jpg)

At this point I did some measuring of the ports, the stock manifolds and the new Pro Flow manifolds
The port measured 1.310" wide
THe stock manifold was a much wider 1.510"
The Pro flo manifolds measure 1.470" which are a tad smaller than the stock manifolds, but still larger than the port. The magic is in the bolt holes. The stock manifolds have larger holes for the bolts than the pro flow's thus necessiating the extra cushion with the opening. Mr. Rick manufacturers the pro flow manifolds with small diameter percision holes which tighten up the "wiggle room" substantially making for a better and more percise fit.

That precision showed up when I decided to test fit the passenger manifold. It fit straight up and every bolt went right in with no fuss at all!

Here's the stocker and Rick's manifolds side by side:
(http://i.imgur.com/TDi5HNW.jpg)
(http://i.imgur.com/WHOLmNe.jpg)
(http://i.imgur.com/fWT3F0q.jpg)

That last shot showed the stud removal tool I used to pull the factory 2ea studs out of the head prior to reinstallation of the Pro-Flow manifold.

Here is the assortment of factory hardware and the cool stainless cap screws which Pro Flow supplies for their new manifolds:
(http://i.imgur.com/YNFuyCA.jpg)

Here's some shots of the stock gasket held over the ports from various angles. You can see the port position is excellent relative to the gasket!
(http://i.imgur.com/CXU3uY6.jpg)
(http://i.imgur.com/vevab5Y.jpg)
(http://i.imgur.com/1mD6EJ4.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 07:58:23 PM
Here the manifold is test fitted showing its position relative to the "old" up pipe. As a reminder, this is an Alligator Performance up pipe used with teh EGR delete. You can clearly see, Rick has taken advantage of the extra room available to stretch things out in going after better flow.
(http://i.imgur.com/BB1TqZw.jpg)
(http://i.imgur.com/0bx171C.jpg)
(http://i.imgur.com/p8nIdoH.jpg)
(http://i.imgur.com/CGfVINF.jpg)

It was necessary to remove the air intake pipe to gain access to the upper up-pipe to pedestal bolts. Not so difficult with the EGR cooler out of the way.

This was as far as I got today, back to it after I vote in the morrow...
(http://i.imgur.com/k4MShGI.jpg)

Well the beatings will continue until morale improves!

I spent 7-8 hours on the project today and can not claim victory...yet!

This job is something like the EGR removal, although I still have to give that the nod as being the single most difficult thing I think I ever did with trucks. The trouble with this manifold and up pipe swap is that you just can't get to anything. Then on top of that the amount of torque required to bust loose those up pipes is astronomical. I mean it must be in the hundreds of pounds times 6 bolts.
Never the less, I'm in it to win it so I pressed on. First I removed the passenger up pipe, the alligator piece I installed some months ago.
The gasket clearly showed I had a small leak, but I didn't hear anything and the engine made upwards of 30psi when I stepped on it
(http://i.imgur.com/V2LZZ39.jpg)
(http://i.imgur.com/aI0F8y1.jpg)

Next I removed the drivers side up pipe bolts at the pedestal. The bolt on the underside of the flange took me over an hour to get! I had to create a tool, and even then, a buddy who stopped by was the one eventually claiming success on that monster.
While he beat himself to death above, I was in the drivers wheel well removing the heat shield from the manifold and the up pipe:
(http://i.imgur.com/zRhLlH3.jpg)
(http://i.imgur.com/9B0XxLX.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 08:03:06 PM
With those out of the way, we, well, he pulled the three manifold to up pipe bolts off and after some pounding twisting, forcing, and rangelin' we freed that pipe. It comes out all the way over on the passenger side up past the turbo!
(http://i.imgur.com/icxD3oV.jpg)
(http://i.imgur.com/mqHENTq.jpg)
(http://i.imgur.com/yUQAgEV.jpg)
(http://i.imgur.com/zkfE8Zi.jpg)

Gentlemen, that drivers side factory pipe is just awful! Take a look at just how restrictive the ports are and how many places it is crimped compared to Ricks excellent pipe:
(http://i.imgur.com/FDHIySo.jpg)
(http://i.imgur.com/CZtWxEr.jpg)
(http://i.imgur.com/3odDQa8.jpg)
(http://i.imgur.com/BfyZz2G.jpg)

Here, I'm pointing out some of the crimped up areas. Notice how smooth the Pro Flow pipes are? Dunno, but I think I'm looking at a sinvificant flow (power) improvement.
(http://i.imgur.com/QHYBLSg.jpg)
(http://i.imgur.com/t4xEIxd.jpg)
(http://i.imgur.com/GRjn7Vg.jpg)

Here's the passenger up pipe compared to the excellent Alligator pipe used for the EGR delete:
(http://i.imgur.com/yDvorPc.jpg)
(http://i.imgur.com/EVcveJU.jpg)
(http://i.imgur.com/01rFstv.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 08:07:23 PM
...and how the drivers manifold and up-pipe fit together:
(http://i.imgur.com/Xyvlv2W.jpg)

Ahhh, that was good...put jalapena's in the sauce!

So next I worked on pulling off the drivers manifold. It was definately way more difficult than the passenger side which is really a breeze, but the jungle of wires masking every square inch makes getting around quite challenging. You will also have to pull the stud out at either end of the factory manifold before you can remove the manifolds because of its proximity to the fuel lines and a bunch of other things.
Oh, forgot to mention, you will need to disconnect the steering column, but that is way easy. 1ea. 15mm bolt and the shaft collapses, then folds forward out of the way.
(http://i.imgur.com/nldz0d1.jpg)
(http://i.imgur.com/FYYc9jW.jpg)
(http://i.imgur.com/hzWfyzJ.jpg)

Then finally, the manifold yields!
(http://i.imgur.com/u2y3hWI.jpg)
(http://i.imgur.com/yxp0WuV.jpg)
(http://i.imgur.com/lH3eHNh.jpg)

Once you wiggle the new manifold in there, it goes on fairly easily. Here's a trick I use to hold onto things that want to fall apart. I coat the bolt with a heavy waxy grease, then slide it into the socket. The grease holds it all in place while you fuss around aligning everything. Rick supplies stainless allen-head screws which I coated with anti seize prior to installation. Note here: whenever installing stainless into aluminum, to prevent gauling, use anti sieze on the bolt.
(http://i.imgur.com/bvJS3mY.jpg)
(http://i.imgur.com/XEFMMBe.jpg)

Relatively speaking, the upper manifold bolts go in easily, however the lower bolts are all hidden by various things like the frame and can be a bit challenging. But as with all things, time and preserverence will get it done. I finished the day's work with installing the drivers manifold and reassemblying the steering column.
(http://i.imgur.com/00Uz0fC.jpg)
(http://i.imgur.com/oetv16U.jpg)



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 08:08:47 PM
Quote:
Originally Posted by D***
"Wow. You must have the patience of a saint."


Not any more!

This manifold swap is really starting to kick my butt!
Just like the EGR delete it is just slow going. Everything is a struggle to get out or back in through the web of wires all over this truck! I worked many hours on the truck today and am not all that much farther along than yesterday.
I bolted up both manifolds. THe underside bolts on the Fro Flow are completely hidden for the most part because of the larger size of the manifold and because it sticks out much farther. So that was a back numbing chore. Once I got those, I started wiggling the drivers up pipe into place. I want to get the hardest stuff out of the way first so that the job theoretically gets easier as I go.
Well, note to self and to all. Make a good study of the gaskets and how exactly they fit. There is 6 possibilities for each gasket. If you're anything like me, you can easily stretch that into 14-15 attempts by forgettins which hole or side you used last time!
So after hours all I had completed is 5 of the 6 12pt bolts started, none tightened. Yes, that's 5 not 6. The 6th would be the one at the pedestal mount on the bottom of the flange. While hunting for the hole with the boly while my shoulder was dislocated (necessary maneuver to get you hand down there) the bolt slipped out. That happende between 1700-1730. Finally at 2000 I gave up. I decided that a worm hole opened up to a parallel universe and that is where that bolt went. I mean it is G O N E! Addios, see ya, alviterzen, sinanora way out of existence gone. Maybe it's inside the oil pan or maybe the fuel tank. THose are a couple of the places I didn't look. There was a dog and a cat near by. I have both tied up and I fed them ex-lax just in case...!!
Well around 2000 I grabbed bolt #2 and just as I started to dislocate my shoulder and elbow this time just to give myself a better angle, tink-tink, it went away as well. I didn't notice any light pulsating so I don't think the worm hole reopened, and I pinched myself on one of the remaining patches of skin that isn't all torn up from three days of self inflicted abuse. I was definately awake, not dreamins, so all that must have happened.
Now the cool thing is those bolts are stainless...Yes, you're correct a magnet will not attract them. I broke out my wife's compact and using the mirror at a crazy angle saw for the very first time what all that looks like down there. Two things: scarry place, no bolt(s).
So I'm on line pricing out my new Cummins truck. I'm junking the Chebby, It has beaten me nearly to death and I don't even like myself anymore. It is just too much and it has won. I not only threw in the towel, I threw a couple of them around a little while ago. SO don't talk to me, leave me alone, I'm done, I'm leaving!


Quote:
Originally Posted by FC5452
"Uh oh, If this is whooping you Don, I may second guess myself on that project. Nah, I refuse to let a monster get the best of me. I will admit after a day on the egr some things where taking me to the edge.
It helps that I have small arms and can get them stuck in places they shouldn't be LOL. I will have to look at this with open eyes this time.... I'll give you to 0100 and an epiphany will come over you. May the diesel gods bless you"




Funny you mention that 0100 time.
I had a dream
and in that dream I saw a bolt
It was resting comfortably on the top of the transmission
So in the same dream I worked out a recovery procedure.
I plan to drag a coat hanger or something somewhat rigid over the top and use it to drag a towel over the top, which will hopefully sweep anything on top of the trans onto my shop floor, which for the moment is devoid of dog droppings. Well, maybe not, the woman unit put the shepherd out in my garage last night about when I was having that dream, so who knows for sure.
In my life I always have to do work to be able to do work. I'll have to clean the garage floor before I work, then I'll have to fire up the fan and the torpedo heater to dry it off. I need diesel for the heater which I will have to drain out of the tractor. I'll have to pull the tractor out of the basement to do that so I don't leak fuel all over the floor. The Harley is currently behind the tractor and it is hooked up to the trickle charger which I will have to disconnect, well, you get the idea...

Quote:
Originally Posted by KensAuto 
"I would have just left those 2 bolts out, to heck with them if they dont want to participate. So what, it might whistle when u step on it, recalibrate your boost gauge to compensate for loss of pressure. Yes, that is what I would do as sure as Don would give up and buy a dodge"


Got me there!
With one caveat
While keeping my D-Max I would be very tempted to turn away a 12 valve dodge 3500 dually in good shape (if there is such a thing left on the planet!) to add to my collection!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 08:53:39 PM
Quote:
Originally Posted by FC5452
"And this is the reason I keep in tune with this thread Don. Humorous, Rhetorical, Instructional, and down right one of the best reads going these days on the forums. I know i have thanked you privately a few times, but thanks again for putting this thread together for us. I'll be trying a few things over the winter myself, Gonna try the Fass Dummy cap on the stock filter and put a Low pressure gauge on it to monitor the LP, and have begun a mock up of the Passenger side IC, Time to get rid of the grid heater and the crossover and puny intake" 

I like the way you are thinking with the intake issues. While you're at it, take a look at the Banks manifold. That thing solves all our intake restriction problems. Not saying I might not be interested in taking a stab at that one!

Quote:
Originally Posted by FC5452
"Made a couple of calls Don, and a few emails are out, one thing that has to be addressed is the MAP sensor port, Though talking with H&S a bung could be installed to mount the MAP. The rest of the plumbing would be some ping and a boot. Free flow without restriction by elimination of the Grid Heater and the air meter(Throttle body as it were) The latter is disabled by the tuning, hence it being unplugged, Though I am awaiting an answer from Industrial as to why it is re connected after the install of the compounds.
Inquiring minds want to know  I have all winter to get this done I'll scope out banks as a solution as well."

Posted by Rick at Profab:

There's restriction further down that will be an issue.
(http://i.imgur.com/lVQBf8b.jpg)
(http://i.imgur.com/0Uwj1XD.jpg)
(http://i.imgur.com/oTwCRsF.jpg)

Posted by Flyin6:
Exactly...
Now
Check out the banks setup
They start at the head and eliminate everything, both manifolds, the Y-bridge intake thing, S tube thing, everything. Problem is it has not been done on an LML, but to the guy who does comes 16 ports of free flowing boost. No telling what numbers the stock turbo could make with that intake!

Posted by FC5452:
I've looked at the banks system Don, that's ok if your building a dedicated drag runner. Rick thanks for those pics, I've had mine tore down, the y bridge, crossover and manifolds are all an issue, hence why I have been picking your brain as well as others.
Increasing the port to the y bridge with the proper channeling to remade manifolds would ease that restriction. There is a y bridge out and manifolds for the lml a new ic pipe would have to be fabbed as well as two ports for the sensors.
(http://i.imgur.com/yTek9Z4.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:03:58 PM
Well, I only got a couple/few hours on the manifold swap project, now into day 4 and, well, it was not a good day.
I tried to find that missing bolt which after the 2-3 hours I was not able to do.
So I need to pick some smart guys brain.
If you are looking at the drivers side up-pipe at where it bolts into the turbo pedestal. Referencing the bottom bolt, if the bolt literally dropped out of that hole and fell the 1 inch to the engine block and then didn't seem to go anywhere else where could it possibly be? Not withstanding the wormhole thing as now a very real possiblity, some demon playing jedi mind tricks on me, or other far reaching but now possible alternatives where could that bolt be?
So remember the REM1 idea of dragging a towel across the top of the trans in an attempt to sweep the bolt free? Well, it was a green towel, relatively new and intact. It is no longer in a pristine condition. It is in fact no longer much of anything. I pulled so many times and with enough force to actually peel some decal off the top of the trans which of course, I didn't even know was there! So safe to say, no bolt up there!
Next I got the rather brilliant idea of using suction in the form of a shop vac necked all the way down to about 3/4". I tested it on myself, quickly removing a nasty mole that was troubling me for some years. I then vacuumed up some concrete, ie, it sucked the smooth layer of concrete off it's base. OK, well maybe I'm exaggerating some, the mole is still partially there, but all the hair surrounding it is gone.
That yielded no bolt either. So then I got another idea. Use high pressure water to blast it out of wherever it was. I did so for a few minutes, all the while thinking something wasn't quite right, but disregarding the knawing feeling, i pressed on. While pulling out the hose I bumped the trans dipstick which pivoted easily, reminding me it was not actually plugged into the transmission, I had removed it to give myself some room. Yea, water, open hole, transmission fluid...
Like I said not a good day!


Posted by FC5452:

Don there's a lip where the bell housing bolts to the block. There is a void behind there. If you did not here it bounce then it dropped in that void. I'm betting that's what happened to my v band
(http://i.imgur.com/47s2ncv.jpg)

Yes, I can feel it and can buy that, however, comma, there is no way I know of on God's green earth to fish something out of that void. How deep do you think it is, 2-3 feet? Somewhere in the neighborhood of 70 cu.in.?

....Quote:
Originally Posted by sammconn View Post
"Don, been keeping up since the beginning, do you or anyone you know have a bore camera? That would get in and let you see in the abyss. Awesome truck."


Bro, you just gave me an idea!
I'll hang my camera down there and snap a dozen or so shots and see if they reveal anything!
Great idea!

Took those pics by suspending my camera back there in the unforseen places and snapped a passel of pictures (A lot).
Look what I found:
(http://i.imgur.com/1fqWvaM.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:07:47 PM
If I didn't say it before, let me say now that all of the problems I had with this thing were Don generated. About the only part of it that went well was anything that to do with THose Pro Flow manifolds and up pipes. I dropped the bolt, then another. Today a 12mm socket. I washed out the inside of my transmission. I did this and that, but when I finally had some clear running, those manifolds nearly fall into place. If I hadn't lost that bolt on Monday, then by 10Am on Tuesday I would have been driving that truck.

Today after I decided to give up on the bolt recovery tabacle, I grabbed one ot those 12mm 12 pt bolts. Placing it in heavy grease and inserting it into a socket on the end of a 3" extension, I carefully moved it into position. My body has learned the location of that hidden bolt hole so well that almost in one motion, I inserted it and started turning it. I put the ratchet on to start to turn it in and immediately it became difficult to turn, then just stopped!
NOOOOO!!! I just didn't do the unthinkable and strip that satanic bottom bolt hole did I????

I felt around the bolt and it seemed to be bottomed out. Hmmm
Using the frau's compact mirror again, I could see the bolt was tight!
You see here's the thing. THose bolt holes in Rick's up-pipes are so percise that the bolt turns in with almost no resistance! I thought it was just starting, but it was almost fully tightened!

That's the way it all went, the up pipes went right on as if they had always been there. They are truly great pieces of hardware!
(http://i.imgur.com/d9d9Inh.jpg)
(http://i.imgur.com/jUghNyU.jpg)

With the amount the new manifolds stick out from the block, I had a proximity issue between the fuel lines and the manifold flange. I solved that by bending the lines further away, then wrapping them with heat proof thermas insulation.
(http://i.imgur.com/dP7MKnk.jpg)
(http://i.imgur.com/Yv2bB8w.jpg)
(http://i.imgur.com/Vj49Sxs.jpg)

Here they are wrapped and secured with stainless safety wire
(http://i.imgur.com/1UhKTiH.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:10:44 PM
Next I installed Alligator Diesel 3" intercooler pipe which Holton sent me some time ago. It had been sitting on the shelf long enough for a spider to build a web, which was invaded by a larger more agressive spider which had also expired on that cool pipe. About a million baby spiders, however were doing just fine, but had they're date with destiny when I "cleaned" them up with a spray of brake cleaner. The spider infestation-free pipe installed as shown:
(http://i.imgur.com/wFLCClb.jpg)
(http://i.imgur.com/7jYIDro.jpg)
(http://i.imgur.com/Zn8Xeog.jpg)
(http://i.imgur.com/nk987wV.jpg)

Then:
(http://i.imgur.com/AaBTQr0.jpg)
(http://i.imgur.com/68PtquT.jpg)
(http://i.imgur.com/YjNZwxY.jpg)

And finally:
(http://i.imgur.com/07flqxe.jpg)
(http://i.imgur.com/YHqTAzY.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:13:35 PM
At this point I had cursed the pipes, tools, myself, the truck, GM, Ford (just cuz) and everything else, so when I set the passenger side pipe in place, I tossed the bolts in there and it self installed!
You may notice the one obvious unauthorized bolt taking the place of our fallen sentinal! May God rest it's eternal ferous soul!
(http://i.imgur.com/N5fo7FM.jpg)
(http://i.imgur.com/uLvETdg.jpg)

I used the heat wrap on the cable bundle near the manifold as well, then pulled it as far away as my spindly tie wraps would allow!
(http://i.imgur.com/ZP9LOdb.jpg)
(http://i.imgur.com/mScydGo.jpg)
(http://i.imgur.com/BB1TqZw.jpg)
(http://i.imgur.com/fdg8UCX.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:15:23 PM
Getting close, only the down pipe, air intake hose, and fender wells yet to install and I'll be able to claim a hard won victory in the campaign to do something with my truck.
Overall and as a general comment, considering all the junk GM puts all over this engine, installing the up pipes and manifolds is a little like installing new piston rings in your engine while accessing the engine through your tail-pipe!
But now that I'm almost there, I am eagerly awaiting starting the engine and driving the truck to see w=how it behaves and sounds. Holton speaks very highly of these manifolds and says they actually change the sound of the engine. Talking with Holton today, we were discussing the cross section of Mr. Ricks manifolds vs the stockers. The new pipes are just huge compared to the choked down stockers. Holton got all technical about drive pressure and things like that, but the bottom line is these manifolds and pipes solve all those problems and make the engine, well, happier!
Nuff said tonight. My left pinky has fallen asleep just like the rest of me is going to be in about one five minutes. C-YA!
(http://i.imgur.com/JgvrYUc.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:22:54 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:25:03 PM
Ah, and I have to self report here:
I said I wasn't going to buy any more parts until I got all the stuff that was spider infested, installed.
Well, sadly, I was not able to exercise self control. While talking to Holton yesterday and while talking about the possibility of getting some water into the trans oil, somehow I ended up buying a deep trans pan! Shame on me!

Then that started me looking at the gator. Realizing I was missing a winch mounting plate for the promark winch box which the cats have been sleeping on, I bought that as well. Probably a mouse nest inside the winch box.

The real issue is my garage windows. The view outside is not that great you see, and all those boxes piled high on the work bench obscured that view. Now that the boxes are now down to a single layer, I have to once again contend with that view...

........I pushed the project ahead today almost to the finish line. The down pipe is connected, wires are reinstalled, bolts tightened, heat shield is back on the turbo.

I still have to connect the air intake duct, install both fender liners and fill the transmission.

Remember when I accidentally got water into the transmission trying to wash that bolt out of it's final resting place? Well Holton suggested I drain the fluid and replace. I was a little uncomfortable with that option and decided to pull the trans pan. Since I was doing that, I went ahead and purchased a PPE deep trans pan from him so I would be sure there would be no water to cause in havoc in that expensive Allison.

The trans pan arrived today so I took the time to install that in lieu of finishing the exhaust install.
Here's the pan:
(http://i.imgur.com/OtP0C0g.jpg)
(http://i.imgur.com/ps8beGQ.jpg)

It came with a filter with a longer neck, but is basically the same design as the stocker.
(http://i.imgur.com/Nhtz25d.jpg)
(http://i.imgur.com/JlgelC8.jpg)
(http://i.imgur.com/rcjKzNw.jpg)
(http://i.imgur.com/a4OQTYP.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:38:52 PM
I decided to modify the "decor" of the PPE pan by sanding off the powder coating from the fins, then recoating everything with my favorite Shark Hide metal coating
(http://i.imgur.com/YAwtJOg.jpg)
(http://i.imgur.com/w5ys0f4.jpg)
(http://i.imgur.com/O0RcHqw.jpg)

I opened the drain plug in the stock trans pan and allowed the fluid to drain for an hour or more. I was surprised to discover when I pulled the pan off that there was still a lot of fluid remaining, maybe as much as 3/4 of a quart.

I poured that off and look what was still in the pan below that oil:
(http://i.imgur.com/KPcC4Bl.jpg)
(http://i.imgur.com/yTUmcUK.jpg)

That's water droplets there in the oil pan so even though I had drained the oil, a small amount of water would have remained and would have possibly been mixed with the oil and circulated throughout the trans. I am now happy that I took the most conservative approach and decided to pull the pan.

Here's the PPE pan installed under my truck:
(http://i.imgur.com/AGmLo2c.jpg)
(http://i.imgur.com/2JQ8XnB.jpg)
(http://i.imgur.com/dwb3GJ0.jpg)
(http://i.imgur.com/IkJplpN.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:46:14 PM
Next the up-pipe went on
I think I have the thing figured out finally.
First the installation technique: When you get it wiggled up and into place, stuff a rag between it and the firewall. THat will hold it in place while you work the V C band clamp into place and carefully tighten the nut.

Here's technique #2: Purchase a couple regular non locking nuts and spin those on. Pull the clamp together with one hand and spin the nut down with the other. That will prevent you from wiggling and moving the clamp with a wrench or ratchet which causes it become disconnected and the up-pipe to fall out of the turbo bellows. Once you get it hand snugged, use a gear wrench with the clamp oriented as pictured which is a much better orientation than the factory position. Once you have it snugged up, then you can spin the locking nut onto the threaded stud and tighten it down against the 1st nut. Try it, you'll like the results!
(http://i.imgur.com/DAd35gB.jpg)
(http://i.imgur.com/Aw6qqxP.jpg)

Double nutted clamp stack-up
(http://i.imgur.com/l8IEhBJ.jpg)

Then I scratched up the new intercooler pipe by dragging the turbo heat shield all over it, but finally something gave way, and the heat shield yielded.

I also noted the proximity of the trans dipstick to the intercooler pipe, so I installed a rubber spacer to prevent future contact and an unexplained buzzing sound
(http://i.imgur.com/hk9B0f4.jpg)
(http://i.imgur.com/SuYAXqp.jpg)

If you guessed that was a short section of unused fuel hose turned vibration absorber, you're correct. Tomorrow, I should finally hear what it sounds like after installing the air intake duct, fender liners, and filling the trans

Quick question: How much fluid, ballpark speaking will I ahve to add to bring that new super deep trans pan up to full? I purchased 8 quarts not knowing for sure...

.....So, the entire capacity of my truck's trans is 7.4 quarts. that's fluid trapped throughout the transmission, in the converter and in the pan. I'm guessing half of it in the pan, say almost 4 qts. I have 8 on hand, sounds like I guessed lucky!

Quote:
Originally Posted by KensAuto
"just the drain and refill w/filter change is 7.4, total capacity is 12.7...plus deep pan "

Rutt-Rrow!!!!!!!!!!
Looks like I'm a gallon short!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:50:14 PM
                                                                                              (3178)
Update on the manifolds: I drove the truck all over today. It yielded good economy and great driveability, but here's an unexpected plus. During the short blasts this morning I could only get the EGT to 1202!

Later in the afternoon, while climbing a two mile hill coming out od Cincy, I nailed it and stayed into it, but it hit the speed limiter pdq. The max I saw and just for a second was 1255, it then slid back to 1247, then tapered off from there. I called Holton while driving to let him know. He said these motors will show a lot less EGT once you uncork them.

BTW, have been trying to post a vid of the exhaust tone, but it won't load. Also noticed an avi is not a supported file. So how does he do dat?????????

......Quote:
Originally Posted by FC5452
"Nice to hear that it worked out for you don. Considering the extra weight you added and all 1200's are nothing to worry about."


Sent from my iPhone using AutoGuide.com App

I'm definitely WAY good with 1200's. When I add the H20/Methanol spray, I expect those numbers to fall again. Then with the twins, yet again. Before I'm done I'll be blowing ice crystals out of the exhaust pipe!

Quote:
Originally Posted by L*********
"Don, since no clip can be uploaded.... can you actually say whether or not there is a change in exhaust sound?"

Yes, it sounds different. At an idle you hear the hiss louder than before. When you tap the throttle and the IGV's change their pitch angle, you get a deep rumble. There is just more of everything. You can tell the factory junk is really plugging the system up. Also when you gun it you hear the turgo whistle as it spools up, which it does very quickly. Driving it at speed, you can hear a deep almost glass pack sort of rumble now that wasn't there before. Most remarkable, though is about 100 degrees of temp that is no longer there!

 
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 09:59:47 PM
Out looking at a farm today I think I am going to buy. I figure the whole castle is not far from tumbling down, so I'm cashing out. Guying a place so far back up in the middle of nowhere that there isn't even an address. Really, you have to drive back about a mile and some change on a nearly 4WD only road (which I will own) just to get there. THen the thing is so old the deed lays the land from a rock to a big white oak to a bend in the creek and so forth!. Realy a nice place, well great potential, but run back to about the 1700's. Anyway gave the truck one heck of a workout. Definitely flexed everything in that suspension as far as it will go. Never even came close to getting stuck. Barely used 4WD, that Grizzley locker back there just pulled us right through.
I think I am going to buy it. It will be a cash deal. I will not owe a penny for it from day 1! We all talked about getting together and playing with our survival trailers, trucks, heeps and so forth. Well, we're coming to my place. It's a hunting only farm. THe fish and game folks keep tabs on it because it was the site of the deer repopulation effort for eastern KY. There are game cams everywhere. On the computer recording all those deer, they have identified 40+ which they believe will be boone and crockett near record deer and another 300+ of "shooters" which will make a turd and just before that a pretty good roast.
Anyway some shots of the truck working it:
(http://i.imgur.com/g5aVQpG.jpg)
(http://i.imgur.com/3QP5GoI.jpg)
(http://i.imgur.com/CmlUoTb.jpg)
(http://i.imgur.com/TTGRWHJ.jpg)
(http://i.imgur.com/FxoJ7Ci.jpg)
(http://i.imgur.com/CkNOhAa.jpg)
(http://i.imgur.com/29qcuil.jpg)
(http://i.imgur.com/jnwDSvL.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 10:09:33 PM
Quote:
Originally Posted by Armalite
".......Don, you call that mud?? I think even shawn could have navigated those trails in the Ferd....."


Mud, are you kidding! That is the worse! I've never seen such conditions. My suspension flexed inches at times! I drove over bumps! There was super narly looking terrain in view at all times. Thank the heavens there was no nasty mulch to get stuck in. There were times I hit ruts that caused the truck to actually rock slightly side to side.
It was awful. I'm currently half way through a total redesign of the suspension to be able to handle even bigger bumps, say 6" or greater at speeds of over 10mph! Serious stuff, but I think with some rockwells, 66" ag tires and a bush hog crew working in front of me, and well a couple tractors pulling box scrapers, I should be much more off road capable!
For now, back to the mall to stuff not quite as rough!

Quote:
Originally Posted by B*****
"What is your all-time favorite helicopter?"

MH-47's
I flew a lot of different models of Chinooks in many different places in the world. I guess the missions in the MH were the most "adventurous" but a normal 101st Airborne Ch-47D was a real work horse pretty much capable of doing anything I ever asked of it. It had so much power, I could climb from the ground to 10,000 feet without any forward airspeed, and do it PDQ. I remember the jumpers would ask me to give them a 1 minute warning before passing 5,000 in the climb. That's where they set their AOD (parachute automatic opening devices) to open the chutes in case they became incapacitated in the exit or in free fall. Things happen, guys run into you, equipment knocks into you, you catch something unexpected on the way out of the ramp. Anyway just as I pulled power to take off I'd give them the 1 minute warning! Yep, it climbed that fast. I'd slow to like 60 knots, then pull around 80% power, which I believe a Black Hawk hovers at (A Chinook hovers at 40-42% power leaving huge reserves for picking stuff up like John Deere JD-550 bulldozers! Anyway with the power pulled in, I'd ask the junior pilot to lift his leg off the floor. We were actually pulling "g's" going straight up with muscle alone. Hey if you like 540 BB Chevys and build D-Max engines you couldn't help but love a Chinook. It is truly the Army's work horse in the stan, able to heft pretty good loads up onto those mountains.
I remember flying the Super Huey gunship over there. There was a place where I used to cross a ridgeline in the Hindu-Kush mountain range. The lowest spot I could find was 12,300 feet. Some days we would climb and climb and circle and try to catch an up draft, but have to turn back because the aircraft couldn't struggle up and over. A hook would laugh at that!
(http://i.imgur.com/BIhhZ5p.jpg)
(http://i.imgur.com/ftaTVOw.jpg)
(http://i.imgur.com/FW5rPng.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 10:15:13 PM
Quote:
Originally Posted by WildChevys
"thats awesome! "

Yes it is
That unit is as well. Probably the most skilled collection of helicopter aviation warriors on earth. No one ever had anything that even came close. It was and remains a deep personal honor for me to have served there with those men.

I think I was the 13th guy in the US Army to get qualified to aerial refuel. I liked everything about flying there, the customers, special operations in general, but I never, never liked one second of being that close to a Herc trying to hang onto that hose, That was and is scary stuff. I once did the math. on the right hose if you push in the hose to minimum distance your rotor blade is only 15',4" from the C130's tail! One of the rotor blades is about 27 feet long. The whole rotor system is 60 feet wide. So you are 1/4th of a rotor disk from another aircraft in flight. Yea I know the aerial demonstration teams fly a couple feet from each other, but a wing touching another wing has practically no speed. But that rotor blade tip is nearly supersonic and the C130's tail if effectively motionless relative to the Chinook. If we touch, there is no coming back, it's fireball in the sky see ya on the other side stuff. We would have to do that 3-4 times a night. Yea, at night as in you can't see the herc without nods.
Yep, that was some crazy stuff we used to do and those skilled warriors still do probably this very night somewhere in the world.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 10:15:38 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 10:25:10 PM
Time to add some more pictures and parts
This time I will be installing the Rare Parts tie rods which are massively beefy compared to the stock stuff.
To bring us up to date, you might recall, I had attempted to install these tie rods months ago.
However since my truck also sports the Fabtech lift kit with closer knuckle distances and a different large bore tie rod end, I ran into sever difficulties.
I solved the first by cutting down the real parts units. THat was around 3/4". and since the thread bottoms, I had to cut both the stud and the barrel.
Since these tie rods which use stock Chevy diameter taper ends which were about a tenth of an inch narrower than the larger diameter supplied tie rods, I had Rare Parts manufacture up some trick double taper sleeves. They are tapered both inside and outside, and fill that space rather nicely.So here is the install. Since we would be doing a lot of messing with the length, I decided to do the install on an alignment lift.
I said I, but what I really meant was Mark, shown here buried in the front suspension and Shannon of Tire Discounters.
(http://i.imgur.com/kGto0Hm.jpg)

It's not often I get to photo other folks working on my truck, but Shannon, the manager of the tire discounters store in Walton, Kentucky shown here is super friendly to 4 wheelers and guys like myself doing other than normal stuff.
Here he is shortening the remaining inner tie rod the necessary amount
(http://i.imgur.com/mCrkX3K.jpg)

When the guys popped the existing tie rod out and dropped in the modified unit, you can see it fell right in place
(http://i.imgur.com/ygqy8BX.jpg)
(http://i.imgur.com/Zc6niiw.jpg)

THe guys bolted both sides in and hooked up the magic to see where the first attempt fell
(http://i.imgur.com/sDJweeU.jpg)
(http://i.imgur.com/LJgMS0P.jpg)

The measurements were pretty good, but not perfect. We had to pull the drivers side out and trim 4 additional threads off both sides to get clearance for a wrench to fit in.
(http://i.imgur.com/rho7AUa.jpg)

For those of you who wonder why your truck rides poorly when you do a torsion bar lift, here's the reason. Your upper control arm (UCA) contacts this stop.
The COgnito UCAs I have installed give you a bunch more clearance and a lot more travel. My truck had so much travel that the rack forward jacks did not have enough travel to get the truck's tire off the rack. THe suspension just kept drooping and drooping....
That's a good thing BTW.
(http://i.imgur.com/4RiFrjP.jpg)

With the additional clearancing, it all went back together and everything lined up well within spec.
I'm not exactly sure how, but I picked up some turning radius. For some reason unless I'm just imagining it, I seem to be able to turn the steering wheel more than before. Anyway the truck drives and rides great and I'm a happy camper.
That was one less box covering the left window (On the right side)
(http://i.imgur.com/H1vc4M5.jpg)
(http://i.imgur.com/DtH3u47.jpg)
(http://i.imgur.com/youQQBk.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 12, 2014, 10:30:22 PM
                                                                                                                              (3342)
I chuckled when I came across this one:
Quote:
Originally Posted by Broc212
"I know awhile back you mentioned you wanted to do a swap from the IFS to a solid front axle. Still wanting to do that if they come out with the kit or is this actually better?"

No, I don't think I am going to do that.
And I don't need a kit, I could design that myself, already put a coil over in a TUndra, and I believe I am still the only guy to ever have done that.
I didn't mean for that to sound like I'm anything special, because I certainly am not, just saying that I don't need anyone to design a kit for me to act on a project like that
Here's why I decided against it:
First the day to day ride of the IFS will never be duplicated by a solid axle.
Secondly the high speed sprint across a field is possible with a IFS, problematic with a SAS.
Next when I looked into it I ran into problems with the 8 on 180mm bolt pattern. First, there are no solid front axles with that pattern so we are talking custom. Next how do I adapt brakes when the 8 on 180 rotors are so much larger, I'd have to cut down stockers.
So if I just swap in a Dodge D60 and go with the 8 on 6.5 pattern then I have to swap something in the rear. If that something is the axles alone to get the rear to a 8 on 6.5, I might have spline issues. Next I am again running into the same bolt pattern issues. The Chevy has larger brake rotors than most of the other trucks so the caliper position would no longer be optimal for the smaller rotor needed to fit the 8 on 6.5.
Of course we haven't even touched on the fact that the braking system will be less effective than the stock Chevy.
With all of that working against the SAS swap, it is just a mountain a bit to big to push out of the way and for what benefit exactly.
No, I believe in the case of the LML and newer Chebby, an improved baja like front suspension and a deaver spring rear with longer travel bigger shocks is the way to go. I believe I can make the suspension extremely capable, and probably for less $$$, so that is the direction I am headed.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 08:54:44 PM
Time to push the project forward some more.
Today Will be the first of what I envision as a two day Amp Research power-step install.
I have had the Amp steps sitting in the garage for some months, and now that I am completely caught up with project Gator, and now that I am getting plenty tired of stretching with my sunday-go-to-meeting clother just to get in, it's time.
Here's what's in the box:
(http://i.imgur.com/vCSgdar.jpg)
(http://i.imgur.com/TnMqiGc.jpg)
(http://i.imgur.com/wiQQBTJ.jpg)
(http://i.imgur.com/0VD8bMz.jpg)

The bracketry, i.e. arms step/board/plank thing, and hardware is top notch. THis is a very high quality kit that seems immediately well thought out. The motors are well constructed, the hardware is coated and more than adequate and every detail seems to have been addressed.
(http://i.imgur.com/Or5sKVt.jpg)
(http://i.imgur.com/ElWGM1n.jpg)

This kit doesn't mess around. THe first thing you do is to attach the front idle brackets to both the body/cab mount and to the lower front fender bolt. That all goes together well, and they even machind a spacer to fit into the recess of the lower fender bolt...nice fit so far!
(http://i.imgur.com/oLop05r.jpg)
(http://i.imgur.com/v6fYEra.jpg)
(http://i.imgur.com/aVSS8X9.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 08:59:07 PM
Then the rear bracket/motor assembly. THe bracket bolts on first using holes already present in the body underside, then the motor gets carefully attached.
(http://i.imgur.com/b4c5ppi.jpg)

The tread/steps are very robust aluminum extrusions of a rough triangle cross section and 85" long. They easily attach with allen head screws into countersunk bores in the arms/brackets.
(http://i.imgur.com/pzGK62v.jpg)

With the radio cranked playing KLOVE in the background this was turning out to be a fun little project. It's just worky, but nothing difficult so far. When I torqued the fasteners in the prescribed pattern everything tightened up nicely and if I held the steps up and released pressure they would gravity lower themselves to the down position. According to the directions this is nominal.
Here is what they will look like tucked up beneath the doors:
(http://i.imgur.com/Pd1uTuw.jpg)
(http://i.imgur.com/ycyyMhm.jpg)

Next the control module gets zip tied to the bracket next to the second battery. The back side of that unit is contoured to fit the tubular bracket to which it is mounted making it a neat and positive installation.
(http://i.imgur.com/Dy20Cep.jpg)
(http://i.imgur.com/MvzQku0.jpg)

First you zip tie it into place then grab the sizeable wiring harness and plug that in.
(http://i.imgur.com/dBORS7b.jpg)
(http://i.imgur.com/Mpudm2J.jpg)

The harness plugs into the module, then the power leads bolt directly to the battery posts. I found the wire lengths to be spot on making for a tidy finish to that part of the installation.
(http://i.imgur.com/QdMW2AG.jpg)
(http://i.imgur.com/btorZEk.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:03:31 PM
The wiring harness drops one leg directly down and routes along the top of the frame rail and plugs into the right side motor. THe opposite leg routes along the top aft of the engine bay, then down along the back of the drivers wheel well and also along the top of the frame to the accuator in the rear mount. I zip-tied as I went and it all went right along with no fuss what so ever.
(http://i.imgur.com/6cSo8s7.jpg)
(http://i.imgur.com/45Qmwvi.jpg)

The harness on both sides has two independent wires coming out of the harness adjacent body plugs. You simply poke the wires up through those plugs (I drilled the right side) then from the inside pop off the sill plate and reach up under the carpet and pull the wires out.
(http://i.imgur.com/AA4iVk7.jpg)

Beneath the sill plate is an wiring harness on either side which you will attach a wire on either side to with a cool little wire tap device AMP Research supplies. I'm liking this kit!
(http://i.imgur.com/ViYs6Zw.jpg)
(http://i.imgur.com/Ww3Gqay.jpg)
(http://i.imgur.com/0sxNU8r.jpg)
(http://i.imgur.com/pbARVFx.jpg)

Next it's on to the removal of the door panels. First off comes the mirror cover
(http://i.imgur.com/pUBAlw9.jpg)

Next the door switch panel is pryed out carefully and the switches disconnected.
This is where I stopped for the night. I only spent maybe 4 hours on it to this point, but I was working slowly, taking pictures and placing extra wire ties in place and things like that. Had I worked like a production shop, I could have been nearly done at this point. It will hopefully be a couple of fairly easy hours in the morning and I should be able to enjoy the use of these cool steps finally!
(http://i.imgur.com/cbrI3P9.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:08:54 PM
Posted by Armalite:
Looks like a nice set up Don. Appears they put alot of thought into their product, which is something that is hard to come by these days...

Why do you have to remove the door panel?? .....
.......Also appears to still be a "grey film" of sorts still on the side of the truck?? I know this truck has never been off road, so I will safely assume it was just the flash of the camera that made the truck body appear to be "dirty", if you will.......

Posted by KensAuto:
^^^^beat me to it !


Posted by STLASER:
Amen Brother! lol


Don replies:
You guys are awful, all of you!
Actually that IS that IS dirt!
Guess where I got it?
From a field with dirt and rocks and stuff to run into and over and all the rest. Lately, the D-Max has been learning to flex a bit. That is other than that horrible stuff over at the mall!

Quote:
Originally Posted by Armalite
"Why do you have to remove the door panel??"


You have to snake a wire inside the door to tap into the one coming from that door open/closed switch. That is where the signal is generated to move the steps.
I just finished, works like a champ. I'll do a picture write up tonight, but I thought I'd twist and torture test them on those speed bumps and mulch pits over at the mall, see if they can stand up to real abuse!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:13:19 PM
All righty, today I finished the Amp Research step install. I have to say that this is one well designed and thought out kit. I have read the critics, but looking at the big picture, I don't care if the gaps aren't perfect, this is no show truck. The steps flot out work. You open the door and they are there. Close the door and they close. They support my weight with no problem and the installation was well thought out.
So I started the day with removing the electric switch panel from the door trim
(http://i.imgur.com/4tas7bP.jpg)

The wire you have to tap into lies within the harness inside the door panel, so that large piece of plastic needs to be removed.
(http://i.imgur.com/V9fCiaJ.jpg)
(http://i.imgur.com/yYTWLFO.jpg)
(http://i.imgur.com/ppZdLst.jpg)

I peeled back the sound proof foam pad, and removed the speaker then carefully threaded a plastic tube from inside the door through the accordian rubber into the cab. I thought that was pretty clever of them (Amp Research) to come up with that idea. You then thread the long wire through the tube, then pull out the tube. You now have a wire inside the door where it needs to be
(http://i.imgur.com/mCQ0IUd.jpg)
(http://i.imgur.com/EJJYL6g.jpg)

I cut into the harness on both doors and spliced into the correct wires, then reassembled the doors. Underneath I used butt connectors to add the 4 LED lights, one for each door, which are held in place with strong double sided foam tape. A few quick zip ties later and it was clean up and test time.
Everything worked fine and this project is now in the bucket!
(http://i.imgur.com/M7dNuN8.jpg)
(http://i.imgur.com/536s7IP.jpg)
(http://i.imgur.com/lZ9PvFm.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:15:01 PM
The mutt didn't seem to care except when I opened the door. She was very interested for about a minute until she figured out a cat wasn't going to jump out. No chew toys today!
(http://i.imgur.com/QXMmy15.jpg)
(http://i.imgur.com/bCVQ9DR.jpg)
(http://i.imgur.com/nWcMyMU.jpg)
(http://i.imgur.com/Hj5PutN.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:19:21 PM
Quote:
Originally Posted by nmeyer414
"Looks good don, but you forgot to wash the mall film off before you took the pictures! Lol! "

That mall stuff won't come off! I tell you, one day I was down there 4 wheelin' around the parking lot. It had a slight grade so I was in low range all locked up...rough, but I was making forward progress.
After the truck sat for awhile, it actually accumulated some dust! Can you believe that?!?
I did what I could carefully but deliberately driving out of the situation. Once I was eventually free of the speed bumps and those slippery and hazardous mulch beds I got it safely to a car wash where after hours of detailing, the truck was restored once again to an operational condition!
I don't talk about that one often, scares me a little...
You think you saw action over in the stan! Ha, you haven't seen anything yet until you try to 4 wheel at the mall on black friday!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:30:16 PM
Got some pics of that new Road Armor bumper which I should be mounting very soon.
The designer there now at their new location has been personally setting up shop and working on this bumper. It is now final welded and the welds have been ground down. Here is the bumper's status as of this past weekend:
(http://i.imgur.com/afVXYL2.jpg)
(http://i.imgur.com/lfuOH7P.jpg)
(http://i.imgur.com/q4L9U98.jpg)
(http://i.imgur.com/EaRR9Ir.jpg)
(http://i.imgur.com/XgEYnR4.jpg)
(http://i.imgur.com/WV6i1mF.jpg)

Quote:
Originally Posted by Armalite
I l"ike that bumper !! That is some very fine precision work! Ready to see what you do to it once it's in your hands... Hopefully it wont suffer the same fate as the GLO differential..."

That's funny!

Well at first I thought I'd just etch it, prime it, then spray it with the Dupli-color bed liner. I really like that stuff and get great results with it. It is also, btw, the exact material they recommend to use to repair scratches on their bumpers.
After that, I want to give them and everyone a good standard install, detailing all of that.
After that, I believe Shawn is tooling up some HD tire rack pieces parts. Using those, I'll build up a super strong rear tire and fuel can carrier and mount a bunch of diesel and water cans. That should be a pretty cool project and really transform the truck into an expo rig.
That's the basic plan so far. I want to also mount the pioneer equipment on the truck. so I will need to find mounting points for a shovel, axe, and a hi-lift jack.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:35:16 PM
Status report:
Been busy with the purchase of the farm...got that done
Currently prepping to buy a bull dozer or compact track loader. Have a lone on a Cat 277B, an ASV SR80, a JD 323D and a Kuboda. Have to figure all that out...tracks not wheels.
Getting a contractor to tear into the farm house. He found 7 foot long snake sking in the floor joists...YIKES!
On the D-Max, I'm waiting to hear back from Road Armor on when the bumper will get here. That is the next project in the breach. Get that installed, the immediately start on the swing away tire carrier/fuel and water can carrier.

So waiting on the man at the moment

Am thinking of modding up a factory Y-Bridge to go from the intercooler all the way to the right and left manifolds bypassing all that LML junk. Talking and ciphering stage on that one at the moment
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:42:15 PM
Quote:
Originally Posted by W*****
"......I know that something needs to be done with the whole induction system after all the deletes we've done. At idle my truck burbles gently for a minute and then it sounds like a waste gate or something opens up and the sound changes completely for another minute and then goes back again... Odd. Really. The revs don't change but I can't help thinking that something is missing and i am sure it is induction related somewhere... "



That change in sound I believe is the inlet guide vanes running a BITE test (built in test equipment). The sound changes from a hiss to a gurble to deep tones and back as the IGV's change pitch. Dammed turbine engines do that too, and sometimes when they are not supposed to. That malfunction can lead to a nasty phenomena called a "compressor stall" which blows fire and engine parts out of either end of the motor. Yep, never liked that one. Sometimes you are lucky enough not only to loose power on that engine, but the sharp parts pierce things like fuel and hydraulic lines, passengers chests, and stuff like that and leave you on fire as well. Talk about your standard bad day...
Did I mention I don't like IGV's??


Posted by KensAuto:
.....to add to Don's explanation, here on earth amongst us peasants (civilian non-pilots) and car guys we call them VVTs...variable vane turbo's.


Dons reply:
From Pilots dictionary of, well, pilot speak, according to, well, pilots:

Non aviator 1. Low Crawler, (Night crawler after sunset) given to low places where there is dirt, mold, moss and the like. 2. Homo-groundas; stands on places not used by wing creations; not knowing of flight also, of limited mental capacity and not very good looking, sometimes called: Ground hog man. 3. Earth-pig; (Modern interpretation) one who grovels in the mud and seldom if ever looks up, thought to be the original two dimensional creature having first crawled out of the primordial swamps. 4. Land rat; one who knows no high places, falls over small bumps and is frightened by ladders, Used as a roosting spot for small birds and large insects.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 09:48:42 PM
......Here's my newest toy:
(http://i.imgur.com/gejPpom.jpg)

Yes Shawn and Ashley, that is ugly paint and a chrome exhaust stack!

Already getting ready to mod it up some.
Carrying it over to the Case dealer tomorrow. Getting a new set of sprockets and rotate the track pins. For some reason I want to paint it OD and mount a big Sun tach on the dash...You know just to say, "It's Don's"
If I came out with a stock dozer, no one would believe it was really mine!

Posted by STLASER:
"This is all crazy" he states as he shows us the purchase made to upgrade the "farm".

Man you weren't kidding that thing is ugly! Lol, I like the chrome stack though. 



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 10:00:10 PM
                                                                                            (3652)
Looky here!

THe designer at Road Armor has the bumper all packaged up and ready to ship. I believe the thing is going to be shipped today or tomorrow, so we will all have a much better look at it in just a few days. You listening Canada?
(http://i.imgur.com/KUbjEKS.jpg)

Quote:
Originally Posted by nmeyer414
"are you excited yet don about the delivery today? "

I am and even more excited to finally see it for myself!
I just unloaded it in the 20F windy conditions outside and have it sitting in my garage!
It's really cool, definitely worth waiting for!
The gentleman who designed it is one Travis Kirkman. He designs most (all??) of the bumpers at Road Armor, and the gentleman who I chatted with during the design of this bumper.
We also talked at length about the ultimate design for this bumper, that being the Expedition truck design I intended for it from the beginning. There seems to be ample strength in it to support what I hope to do, but Travis went even further.
He included the parts for the spare tire carrier he made to actually go down this route earlier.
My hope is to use this design, Nate, no need to ship that HMMV device right now, to add on the spare and fuel can carrier. Here's a sketch of that tire carrier:
(http://i.imgur.com/HFd8ppe.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 10:07:09 PM
Brother Nate, copy all
You wanted pics? You're gonna get pics!
OK so lets get evaluating what we have here with this brand new bumper. This will be the introduction as it were of this part. Road Armor will go into production fairly soon on this part. My job is to bolt it on and evaluate it, then weld all over it and create a full on expedition bumper build.
Let's start examining it
Travis sent a lot of stuff to help me get well down the road to expo complete. Here are some close up pics of the soon to be tire carrier complete with hinge bearing, although we are planning on a GLO part from Shawn to beef that up some more. All of this will attach to other tubing and weld to a 2' X 4" main beam which will carry the weight and serve for a good place for kias to beat themselves to death:
(http://i.imgur.com/JRvnLPl.jpg)
(http://i.imgur.com/4HxX9L4.jpg)
(http://i.imgur.com/pO0EKs4.jpg)
(http://i.imgur.com/ykwmFHr.jpg)

This stuff is put together so well and cut so precisely, I almost hate to weld on it, but somehow, I'll find the courage...
(http://i.imgur.com/DqTEN8V.jpg)
(http://i.imgur.com/IF9ZQLo.jpg)
(http://i.imgur.com/Kc1ds7i.jpg)

Apologies for the blurry pics, but at night with my eyes (once good, but now not so much) it all looks about the same. Go ahead and chuckle, but know what? Yep, it's coming your way as well!
OK some bumper detail shots:
(http://i.imgur.com/5wNxXNT.jpg)
(http://i.imgur.com/KZHhE4u.jpg)
(http://i.imgur.com/wiTuB2o.jpg)
(http://i.imgur.com/He3agVp.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 10:19:50 PM
The dog didn't come with the bumper but the hardware did. at least most of it. Travis is so concerned that I get a great start that he is sending me some additional hardware to attach this to the tow hitch as well. BTW, with the installation of this bumper the towing capacity goes from 20,000 pounds up to just over 246,000 just so I can tow the shuttle plus a crew of fat girls thereby besting the toyota tundra!
Well maybe I exaggerated a bit, that that is the essential makin's of a good story!
(http://i.imgur.com/bFxUc4n.jpg)
(http://i.imgur.com/LMke34J.jpg)
(http://i.imgur.com/zptux4T.jpg)
(http://i.imgur.com/6WfJZ1T.jpg)

More blurry pics of a pretty bare metal bumper
The clevis points are rated to tow medium size jets, say 787 or smaller unless you're using both points then you can jump up to the shuttle and the crew of fat girls!
(http://i.imgur.com/piAdWbQ.jpg)
(http://i.imgur.com/6BD1G0T.jpg)
(http://i.imgur.com/Z1yGFfL.jpg)
(http://i.imgur.com/5UHObYN.jpg)
(http://i.imgur.com/mCXRDVL.jpg)
(http://i.imgur.com/eGtnV7h.jpg)
(http://i.imgur.com/6ql6WOY.jpg)

You can clearly see the addition of holes to properly position the back up sensors and mount the trailer electrical cable. I believe those extra holes serve as a mount for auxiliary lights as well.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 10:28:29 PM
And for Shawn, here's some closeups of the bronze bushing hinge assembly Travis sent up as well as the axle for the wheel mounting flange which I have sitting elsewhere:
(http://i.imgur.com/WQ912Wn.jpg)
(http://i.imgur.com/rdGJaxv.jpg)
(http://i.imgur.com/YRQBK80.jpg)

Quote:
Originally Posted by stlaser
"OK, next question. How long is the piece you are holding up to that 45 degree angle? "

The piece is a solid steel bar which is a cylindrical section (Oglive) that's total length is 9 1/8" and area past the angle cut section is equal to 6.5"
(http://i.imgur.com/BcWs6dG.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 10:29:59 PM
Quote:
Originally Posted by stlaser
"One more question, if top of bumper leveled is zero how many degree drop is that section this mounts too? Is it 45?"

Shawn,
The flat top appears to be parallel with terra firma. The first angle is not 45. It falls away less abruptly than 45. Can't measure right now...
Travis sent up a nifty piece which I just figured out seems to attach to one of the corners of the bumper. If I am correct, I will be able to weld that in place (photo follows) cut out the inside then insert the bronze bushing and the steel axle. It appears as though that axle bevel is pretty close to a match for the inside of bumper. If this is the case, this would be a massively strong attachment for the hinge assembly. I don't believe I would be able to break that on my worst day!
Take a look at the pics I will post in the following posts to see what I am talking about.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 10:38:54 PM
                                                                                                      (3745)
Spent the day sourcing parts and I think I am ready to begin.
I changed the way this is all going to go together. First, I will install the axle assembly for the swing away tire carrier, burying it deep inside the bumper and adding some structure. Next I will create the main beam and build a latch point. Following that, I will remove that, and coat the bumper, then install it. SO the first time it goes on the truck will be in it's modified state. This way I can then reattach the beam and fab up the actual tire carrier and the gas can racks. Then remove that section, weld and paint that, then assemble it back onto the bumper and mount up the spare tire and be mission complete.
So here's what the actual tire carrier looks like fitted roughly together and the wheel mount ring that will be modified to attach to the carrier.
(http://i.imgur.com/0ZSrU6D.jpg)
(http://i.imgur.com/VWwbJUn.jpg)
(http://i.imgur.com/ClNj6g6.jpg)
(http://i.imgur.com/2BprYWV.jpg)

I will be using 2' X 3" X .188" rectangle tubing, 14 and 12 gage steel and 1" 14 gage square tubing for the tire and fuel can carrier
(http://i.imgur.com/gIiWyCg.jpg)
(http://i.imgur.com/21NjXB4.jpg)

The initial fitment is looking pretty good and I am anticipating a good and strong build of the tire carrier.
(http://i.imgur.com/3FBjI7R.jpg)
(http://i.imgur.com/LURXISH.jpg)

The bumper mount brackets look massively strong. I don't anticipate any issues from them with regard to strength.
(http://i.imgur.com/lPDZ7Hn.jpg)
(http://i.imgur.com/Cd7Fqws.jpg)
(http://i.imgur.com/bLfIJBo.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 10:41:08 PM
And finally, the swing away axle mount. It's a three part unit consisting of a collar cut so as to fit over the bumper corner, a bronze bushing, and the bevel cut axle itself.
(http://i.imgur.com/kDLVhJ8.jpg)
(http://i.imgur.com/aCQUSji.jpg)
(http://i.imgur.com/Y1gi8Nf.jpg)

Had Track Loader chores today...no workie on das bumper.
But I did get to discuss, cipher, and think! THe latter caused a small fire, but that's another story...
Travis the brain at Road Armor sent me the following depections of that tire carrier design concept, and I have decided along with Dr. Shawn to go with that plan.
(http://i.imgur.com/vrelLKP.jpg)
(http://i.imgur.com/hijCmX4.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 13, 2014, 10:47:50 PM
I plan to support the main beam weight with a shelf at the lock point and rubber pad all that to reduce rattles to less than that of a new Ford (120db)

Here's a couple pics of the concept for the finished unit. I also plan to add a hi-lift jack mount, a back up cam, and a radio antenna mast, then call it a day.

I tried to order the tire and wheel today, then something happened... Shannon over at Tire Discounters came up with 5 Micky Thompson MTZ, 37-12.50/17's on clearnace for $390 ea...hmmm
Me likes the narrow tire b/c my farm is all mud, so now I am literally 4-wheeling all the time. We can all safely assume that running a 15 ton track loader all over it will do nothing to create more mud, right??

Anywho, here's the general concept:
(http://i.imgur.com/1ONw2jy.jpg)
(http://i.imgur.com/vvVkZP5.jpg)

I just ordered the fuel and water cans for the rear rack.
I have beaucoup experience with the Wedco cans. They are everywhere, used by NATO and all of us who can score some from those armies who like to trade stuff. I picked up two fuel cans and two water cans, all 4 dressed in OD green, the now color I have chosen for Big Red (The Dozer).
I am going to try to squeeze three cans into the design, however, space is going to be at a premium, especially if I go through and opt for the 37" tires. I also want to mount up a small lockable equipment locker to store the spouts, a gas siphon and who knows what else...
(http://i.imgur.com/KOB1SLM.jpg)
(http://i.imgur.com/TPzWgoM.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 08:53:27 PM
Started on the actual bumper modification today. I couldn't get as far as I wanted because Travis is sending me more parts to make the far end of the tire rack beam mount.
Today I concentrated on getting the pivot point axle installed and I did get all that done.
First I worked on the stub fitting which houses the lower oil bronce bushing
(http://i.imgur.com/6LNEjPj.jpg)

After much grinding, I had the fit I was looking for. I drilled out the inside of the bushing carrier, finishing the cut with a plasma cutter and a grinder.
(http://i.imgur.com/tXwPdvT.jpg)
(http://i.imgur.com/rCUd57I.jpg)
(http://i.imgur.com/7XHCXCj.jpg)

The axle had a bevel that fit the inside of the bumper, although not in the way I thought it would have. I had to fit that part as well, grinding some then checking and repeating unitl I had a good fit with that as well. I then welded all of that in place
I used a very high heat setting and a higher wire speed to get a lot of material in there. I believe that weld is up to the task of holding all that together.
(http://i.imgur.com/jI4wiSw.jpg)
(http://i.imgur.com/ap8d535.jpg)
(http://i.imgur.com/jKOWGUZ.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 08:56:39 PM
Next I worked on the main beam bushing sleeve and primary mount. The assembly consists of two oil bronze bushings fitted inside a split steel sleeve. The concept is to be able to tighten the sleeve, thereby providing a clamping force onto the bushing. I hope to control the resistance of the carrier as I open/close through tightening that bushing up.
Travis provided a couple cool bolt sleeves to weld to the split seam.
(http://i.imgur.com/bCZUJ49.jpg)
(http://i.imgur.com/NU16u2c.jpg)
(http://i.imgur.com/MkHxMsw.jpg)

After welding and wire brushing that part is complete and time to fit it all to the axle.
(http://i.imgur.com/1pTSjLS.jpg)
(http://i.imgur.com/m2fozGs.jpg)
(http://i.imgur.com/yw4xHGi.jpg)
(http://i.imgur.com/SasiV6B.jpg)

Here it is fitting to the axle
(http://i.imgur.com/yt7jC8r.jpg)
(http://i.imgur.com/yt7jC8r.jpg)
(http://i.imgur.com/RmGwa1g.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:06:40 PM
Initial fitment of the 2" X 3" X .188" steel tubing. I bought it way too long, not knowing exactly where everything will attach
(http://i.imgur.com/hSvoPa3.jpg)

I'm jumping ahead, but I wanted to show how this thing will fit together. The end with the latch will have a angled extension which will strike a main plate which will act as a positive stop to keep that tire from crashing through my expensive tail light lens and body work.
Inside the beveled end will be this nut plate and to it a poly bumper pad will be attached. All the slamming in the world should produce little more that a mild recoil and never any damage.
This is it for tonight, back to it next time!
(http://i.imgur.com/WXRkGZG.jpg)
(http://i.imgur.com/RHmOD6x.jpg)
(http://i.imgur.com/uLM4fNc.jpg)
(http://i.imgur.com/5dZ8Rvy.jpg)

OK, enough of the chitty chat!
On with the bumper build
Church day today, so I only got a couple hours of garage time.
My goal for the day was to get the swing out beam installed and ready for the next step.
Travis at Road Armor has sent me some more parts to complete the latch and strike plate so I am waiting on those parts to finish the beam and latch fab. From there, it will be on to the actual bumper painting and installation, then I will continue with the fab work and fitting on the beam of the tire carrier and the fuel can carrier.
I started by fish mouth cutting the 2" X 3" rectangle tubing.
(http://i.imgur.com/CmdhWcr.jpg)

I was able to get a good tight fit onto the bushing sleeve/clamp assembly
(http://i.imgur.com/MGzV1x1.jpg)

At this point my gloves needed more work than the beam I was fabbing, but I welded it all up with a hot setting. I was getting great penetration so I am sure this is a strong weld and joint.
(http://i.imgur.com/Zk1JNww.jpg)

It was all sloppy loose until I tightened down the clamp bolts. Then it straightened up and had good friction.
This was the quitting point for the evening. If I don't get the strike plate assembly in the morrow, I will weld up the tire carrier frame.
(http://i.imgur.com/KgouuwQ.jpg)



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:12:05 PM
More progress tonight. After looking at it, I wanted to pre-stress the main beam after reconsidering the load it is eventually going to carry. So I made a thin cut, bent up the bar then rewelded. I can force it down to level, but it has a very slight rise which should be held to level with the weight of the spare and fuel cans.
I also welded up the tire carrier, having to fit some of the parts, but it is done now awaiting attachment to the main beam.
(http://i.imgur.com/hRl6v5c.jpg)

The next piece is added
(http://i.imgur.com/z9BPhXS.jpg)

And some more:
(http://i.imgur.com/S3F5rEd.jpg)
(http://i.imgur.com/1hxen2r.jpg)

On to my high tech steel and cardboard welding table
(http://i.imgur.com/Wf3B2c8.jpg)

Welded and wire brushed
(http://i.imgur.com/VVJg8YS.jpg)
(http://i.imgur.com/gWlezBz.jpg)
(http://i.imgur.com/FXfcC1R.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:16:11 PM
Next I slid in the axle and held the wheel mount ring for approximation. Next up will be the creation of the filler disc which will connect the axle to the wheel mount flange.
(http://i.imgur.com/HhdC5Ky.jpg)
(http://i.imgur.com/yZ6rmGk.jpg)

The tire carrier build continued today. But first before getting into that, some of the stuff that will be residing on this bumper started to come in today
Here's a look:
(http://i.imgur.com/6ZIlHxp.jpg)
(http://i.imgur.com/WihWyK1.jpg)
(http://i.imgur.com/UNcRE0e.jpg)
(http://i.imgur.com/1wSa28Q.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:19:03 PM
Travis sent me this highly angularized (if that is a word) piece of steel to weld to the bumper and act as a strike plate for the main beam closing and latching.
(http://i.imgur.com/WAk2x2b.jpg)
(http://i.imgur.com/SpgKhwL.jpg)
(http://i.imgur.com/NqsI35q.jpg)
(http://i.imgur.com/uVLKfpv.jpg)

I first fitted the piece, then tacked it in place. After double checking that everything would indeed fit, I welded it onto the bumper from the inside.
(http://i.imgur.com/CyXStFh.jpg)
(http://i.imgur.com/UNPyPGH.jpg)

Then I welded on the strike plate
(http://i.imgur.com/hFfnb06.jpg)
(http://i.imgur.com/559IIyh.jpg)
(http://i.imgur.com/ZxdxkaO.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:21:53 PM
Here's a few views after the grinding
(http://i.imgur.com/1UuqzrK.jpg)
(http://i.imgur.com/qaF7xi9.jpg)
(http://i.imgur.com/3PqGKmN.jpg)
(http://i.imgur.com/rhNamMh.jpg)

Next I had to figure out the correct length of the main beam and how to turn it to strike the striker squarely
First the main beam was angle cut
(http://i.imgur.com/0mOEosv.jpg)

Then a ram was created out of the same tubing with a nut plate welded in one end and fitted with a 1/2" thick piece of poly.
(http://i.imgur.com/n4rYhHw.jpg)
(http://i.imgur.com/zcpD4TZ.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:30:16 PM
The stainless allen socket head screws will be replaced with bevel head allen head screws when final assembly comes, but this is good for now.
I had to offset the ram .75" lower so that most of the poly block would actually contact the strike plate.
Here's how that went together:
(http://i.imgur.com/touKipp.jpg)
(http://i.imgur.com/oyn701u.jpg)
(http://i.imgur.com/dm5XxPf.jpg)
(http://i.imgur.com/64OjXUQ.jpg)

I might do something cosmetic to that area where it is obvious that the tube was sectioned and rewelded, but that will happen tomorrow.
I stopped here for the evening. The pic shows the state of the build as of this post. The main beam appears to droop in the pic because the bushing clamp bolts have not been tightened. It all gets level and pretty with a few turns of that 3/8" bolts!

Next up I will fab up a shelf for the beam to rest upon when the thing is in the travel position (Locked close)
(http://i.imgur.com/N8mKG9y.jpg)

So, last night I was all over the innernet just ah' lookin' fer stuff. Latch stuff. All me kan finds is some gud lookin stuf from the england. So's I's gives it up around 2230 to go watch the latest episode of the wedding planner.
So's me wakes up this mornin and me sees a add just sitting there beside all my emales. It is from seers! It's fer a latch handle thing! Jus what's I's was ah' lookin fer. The difference is that's it's $8.99, not the $62 the brits want, then with the VAT, customs, shippin' and so forth, that comes to $7,321!
So's I get's me plastik and orderes me some. komputer says, (Well actually doesn't sez anything, jest spels it all out) I'll have em' by early Feb, and of dis yer!
I'm happy...!
(http://i.imgur.com/XwFdxaa.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:34:21 PM
Posted by nmeyer414:
Attached pictures are numbered from left to right 1-4

the first one was a suggestion for the fact that you can lock it in to place or at least run a pin through it to keep it from accidently coming open

2nd pic of what our current fuel cans look like with an old style metal fuel spout

3rd pic is what our new fuel spouts look like

4th pic is one of what the new fuel cans look like
(http://i.imgur.com/f0d4Awm.jpg)
(http://i.imgur.com/rAgiHrQ.jpg)
(http://i.imgur.com/EOmS51C.jpg)
(http://i.imgur.com/BENoF8r.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:42:37 PM
Gentlemen, hopefully your questions will be answered as you view the build. Nate, good idea on the pin and I love those fuel cans, top notch.
Ironically, my NATO fuel cans started coming in today so I can share pics of them. They are very robust, steel and last a lifetime
Here's some pics of them before I post up the build progress:
(http://i.imgur.com/VS6yeKA.jpg)
(http://i.imgur.com/cdF6HtD.jpg)
(http://i.imgur.com/M4qq0HN.jpg)
(http://i.imgur.com/cbNVTrK.jpg)
(http://i.imgur.com/vyGh17i.jpg)
(http://i.imgur.com/bK86GxH.jpg)
(http://i.imgur.com/tTJhMcj.jpg)
(http://i.imgur.com/YP0nJ5q.jpg)
(http://i.imgur.com/IVLsz2o.jpg)
(http://i.imgur.com/DoPR3wa.jpg)
(http://i.imgur.com/9bgQp4C.jpg)
(http://i.imgur.com/cNXmPBc.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:44:28 PM
Today I wanted to fab up the travel rest pedestal for the main beam and get a latch installed. I got done exactly that before domestic duties pulled me away
Here's the pedestal being created out of cardboard!
(http://i.imgur.com/BZVjJrf.jpg)
(http://i.imgur.com/1AuuYpu.jpg)
(http://i.imgur.com/jxZb3Lt.jpg)
(http://i.imgur.com/8io4SuB.jpg)

Piece by piece I cut the sections out of 12 gage with a plasma torch, then final fitted the parts with a grinder before tacking in place
(http://i.imgur.com/GFoieSo.jpg)
(http://i.imgur.com/pC42xfB.jpg)
(http://i.imgur.com/T8XsjnP.jpg)
(http://i.imgur.com/GrizxzV.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:49:39 PM
I built the top section out of one piece, bending it in the metal brake as necessary to get the fit I wanted. There is a flat section for the main beam to actually rest on and a short ramp, just in case the beam settles any due to the weight it might be carrying
(http://i.imgur.com/QpQGfJv.jpg)
(http://i.imgur.com/FtiFYvs.jpg)
(http://i.imgur.com/lMbCUo7.jpg)
(http://i.imgur.com/O4CwDCz.jpg)

After tacking the top piece on and cutting out the bottom piece. I cut the tack welds and removed the box, then welded the box from the inside with a hot weld that penetrated all the way through.
(http://i.imgur.com/DmMyQRe.jpg)
(http://i.imgur.com/SulmvPQ.jpg)
(http://i.imgur.com/F8tiCkw.jpg)
(http://i.imgur.com/IKZmcoF.jpg)

After cleaning and grinding, I welded the pedestal permanently onto the bumper, then cleaned the welds again with a wire cup
(http://i.imgur.com/FC9mGko.jpg)
(http://i.imgur.com/UpqkxxM.jpg)
(http://i.imgur.com/XsoXa9z.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:54:15 PM
                                                                                  (3844)
I then welded up some positive stops to augument the poly bumper pad
(http://i.imgur.com/cibxPco.jpg)
(http://i.imgur.com/7pfnpdl.jpg)
(http://i.imgur.com/Ud0kPpY.jpg)
(http://i.imgur.com/pFzSvs9.jpg)

I reinstalled the poly bumper and closed the beam in preparation for placing the first of two latch mechanisms
(http://i.imgur.com/DEEteu0.jpg)
(http://i.imgur.com/dwnxe4H.jpg)
(http://i.imgur.com/v9iolhB.jpg)

The latch is a HD sucker. Big strong and sporting a 11/16" steel plunger with a positive latch that will definitely keep the plunger seated
I started by drilling and tapping a small piece of thick angle and bolting that to the latch.
(http://i.imgur.com/EniFRJ6.jpg)
(http://i.imgur.com/yF0E9f6.jpg)
(http://i.imgur.com/VKEvkxQ.jpg)
(http://i.imgur.com/ykbJbEG.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 14, 2014, 09:58:28 PM
I started with a rose weld, but then decided to give the outside edge a pass as well
Then I drilled and tapped the other 4 holes and installed stainless allen head screws
(http://i.imgur.com/hikkuOf.jpg)
(http://i.imgur.com/b1TqPSe.jpg)
(http://i.imgur.com/Ho9URyD.jpg)

While holding the beam tightly closed, I placed a washer beneath the plunger and tacked it in place. I then drilled the hole out resulting in one tight super secure fit and retention of the main beam.
(http://i.imgur.com/864Qk1T.jpg)
(http://i.imgur.com/yA2UQYU.jpg)
(http://i.imgur.com/LmfwOxH.jpg)

So that was mission complete for fab day 5, here's the state of the build at this point:
(http://i.imgur.com/BUcnJNE.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 07:35:39 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 07:38:48 PM
Managed to push the ball down field a little more today, which is day 6 of the bumper and tire carrier build
Today I attached the tire carrier after measuring a couple of times. After that I fabbed up the bottom of the fuel can carrier.
Here's the tire carrier which has just been welded on
(http://i.imgur.com/eI3UxEe.jpg)
(http://i.imgur.com/3jjlvOj.jpg)
(http://i.imgur.com/r8OpPCe.jpg)

Most of the welds turned out fine with one notable exception which has to ground down and another pass made. I believe I must have run into some impurities because all of a sudden the weld puddled and rolled off the steel! Anyway, the rest of it looked OK
(http://i.imgur.com/UJhUVIb.jpg)
(http://i.imgur.com/Sq8xUuy.jpg)
(http://i.imgur.com/GHcUsUO.jpg)

Next up was the can holder. I decided I had room for three cans, this much space:
(http://i.imgur.com/gvfeq9S.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 07:41:59 PM
I think I can find room for additional cans on the tactical topper which is soon to get reenergized.
The footprint of three cans is 21" X 14" which allows room for me to place a sheet of abrasion resistient something between the cans and still get a snug fit.
The bottom was made from 16 ga cut with a plasma cutter.
(http://i.imgur.com/Q9Tsw1g.jpg)
(http://i.imgur.com/Q9Tsw1g.jpg)

The sides were created from 1/8" plate cut the length of two sides, then bent to shape.
(http://i.imgur.com/Lr0Ij22.jpg)

After cutting some holes in the sides to act as drains, I welded it all together. It will occupy a space beside the spare tire, and will fit a tire up to 37.5" OD
This is only the base, as far as I could get today, and will sit approximately here on the main beam:
(http://i.imgur.com/LeWbi9q.jpg)
(http://i.imgur.com/tr5jb21.jpg)

The base will hold the cans securely and provide puncture resistance. The top will provide a means to lock them in place.
The fit is pretty good so far:
(http://i.imgur.com/ddODPpL.jpg)
(http://i.imgur.com/YBPBINA.jpg)
(http://i.imgur.com/kiDulij.jpg)
(http://i.imgur.com/5ERpvbJ.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 07:48:12 PM
Cans removed, back to the cardboard welding table  for more fab, tomorrow that is!
(http://i.imgur.com/X0z6oiX.jpg)

OK, so let's get on with this bumper build. Looking at Day 7 of the fab and build and I think we are getting there. Today I concentrated on the can carrier and got that about 90% done. After that, I have the secondary latch coming in Monday, but I think I have a day of Big Red work then, so that might get delayed a little. After that, it's grind time then painting. I think I will use the bumper coating on the inside of the bumper and any high corrosion or high wear area like the can holder, and possibly spray the rest of the thing with my favorite JD black paint and gun lube!
So, off to the can container construction. First I bent up the top ring, then cut the legs:
(http://i.imgur.com/nwmOSwl.jpg)
(http://i.imgur.com/9wKEUa4.jpg)
(http://i.imgur.com/8V39MYW.jpg)
(http://i.imgur.com/9H9Uphl.jpg)

The corner pieces are cut from 1" X .125" steel angle, 12" long
(http://i.imgur.com/CMVC82s.jpg)
(http://i.imgur.com/uVx7bpz.jpg)

Those were tacked in place
(http://i.imgur.com/HTtu93c.jpg)
(http://i.imgur.com/d3ROWDJ.jpg)

Then the top band was welded in place
(http://i.imgur.com/31GZQUz.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 07:54:34 PM
I spaced the can holder up 2" to give more departure angle since that sucker protrudes back some and to be at a better height to grab from. Lastly I wanted to get a tad more angle on the yet to come support braces
(http://i.imgur.com/1kMvoQ8.jpg)
(http://i.imgur.com/4k49iHu.jpg)
(http://i.imgur.com/ZpB0yVF.jpg)
(http://i.imgur.com/WAPPQgn.jpg)

Next, I welded the can holder to the main beam spacer plate in several places.
(http://i.imgur.com/0QqtBLn.jpg)
(http://i.imgur.com/UpLjjU4.jpg)
(http://i.imgur.com/McVCcDX.jpg)
(http://i.imgur.com/G2hyPMn.jpg)

I got the support risers figured out, angle wise, but ran out of time to make the 4ea of them I am going to weld in place.
Here's how it will fit:
(http://i.imgur.com/YdZEKVG.jpg)
(http://i.imgur.com/AxhJQbL.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 08:02:45 PM
OK, done with day 8 of the bumper/tire carrier expo thing ah-ma-jiggy. I got most of it done today with the can box all mounted and the spare tire wheel flange done, well mostly.
I started with the braces for the spare can rack. Here's how I did that:
(http://i.imgur.com/eZ2MIM9.jpg)
(http://i.imgur.com/cAbwQXJ.jpg)
(http://i.imgur.com/jGuQreI.jpg)
(http://i.imgur.com/3qGEVBw.jpg)

Those attached to both the main beam and the outside edge of the can rack.
(http://i.imgur.com/awMdC0z.jpg)
(http://i.imgur.com/21bFXt8.jpg)
(http://i.imgur.com/hbvqgzS.jpg)

With the family of cans:
(http://i.imgur.com/Nd0ZzjD.jpg)
(http://i.imgur.com/4jOk49v.jpg)
(http://i.imgur.com/OhJ9Xjl.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 08:17:07 PM
With that done with the exception of final welding and grinding, I went on to the spare tire rack again. The wheel has to mount to something so I built that starting with a 8 on 180mm steel spacer ring and traced out a pattern on 3/16" steel plate .
(http://i.imgur.com/0v5UgdV.jpg)
(http://i.imgur.com/o38E1cu.jpg)

I drilled out the axle hole first, then 4 more lightening holes
(http://i.imgur.com/JLoxnIU.jpg)
(http://i.imgur.com/WwJV4e2.jpg)
(http://i.imgur.com/YF6kzcv.jpg)

Next Mr. Plasma did his thing burning steel all over, setting my cardboard welding table on fire a couple times, but no worries we are nearing the end of this project!
(http://i.imgur.com/EGQYQrk.jpg)
(http://i.imgur.com/1JU47Yc.jpg)

For a quick minute I considered using the maltese cross lookin' thing as the flange, but naw, I went for the strength instead.
So with some grinding, I welded the flange to it
(http://i.imgur.com/uHOmj7b.jpg)
(http://i.imgur.com/jiVDUcc.jpg)
(http://i.imgur.com/5QrbrdO.jpg)



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 08:20:09 PM
Dem Dar is rose welds. Not like roses you always forget to send to the M.R.S, unit, nope this is an entirely different rose!
Anyway, it's quick strong and pretty. Shawn likes pretty welds, so the roses are in honor of him!
Next I placed the axle in there then I tilted it. I got the idea from the Earth. You see, it's tilted so how can that be wrong?
(http://i.imgur.com/BZoDaja.jpg)
(http://i.imgur.com/BZoDaja.jpg)
(http://i.imgur.com/qO8zM7P.jpg)
(http://i.imgur.com/hOKHwpD.jpg)

It got together all good and crooked, mother nature was pleased, so I moved on. Here's the thing nearing completion with it's "longer than it needs to be axle, which will get trimmed to size once me gits the spare tire n' wheel!
(http://i.imgur.com/6dtsJUa.jpg)
(http://i.imgur.com/D01P93V.jpg)
(http://i.imgur.com/blPFmgJ.jpg)
(http://i.imgur.com/9sfkYrV.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 08:22:25 PM
So who knows why the thing is tilted other than the obvious influence of the tilted earth thing?
Anyone?
OK, I have to spoon feed you people everything!
Gets you a little more departure angle coming out of a ditch or reversing from down back to up. That extra inch helps. I did it to my Hummer and stopped dragging the tire driving down into the creek!

OK hold on to your kittens we're not quite done yet!
Ever balance a 90 pound tire and wheel about waist high while you align those pesky studs into the wheel holes?
Yea, that...
So I added a hub to the flange so I can heft (Or get one of you boneheads to do it for me) Anyhow, however it gets up there just like playing off road horse-shoes, all you have to do is to get the wheel onto the hub and you're home free.
I'm smart that way and look at the pics, you'll agree!
(http://i.imgur.com/kDSecS8.jpg)
(http://i.imgur.com/GDZ0Xbg.jpg)
(http://i.imgur.com/cnULQI8.jpg)

Here's some more pics. Not that you need any, but I took the time to take them so you can take the time to look at them
There!
(http://i.imgur.com/Hztc1K3.jpg)
(http://i.imgur.com/qKnwhd1.jpg)
(http://i.imgur.com/JdKBSkR.jpg)
(http://i.imgur.com/UETIdNR.jpg)
(http://i.imgur.com/RyGXYSp.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 08:25:14 PM
Quote:
Originally Posted by nmeyer414
"by the way, can we get an update on how the repairs of big red are going and the barn? sorry for the derail "

No worries!
Big red is almost healed
So far they replaced 3 hydraulic lines
New gaskets in the final drives
New trans filter and fluid
Amsoil in the engine
New fuel and hydraulic filters
Final drive and transfer cases oil changed
New radiator hoses
New antifreeze
New track adjuster fittings
New sprockets installed
Alternator rebuilt
New wiring run
Inline fuses installed
Battery cables crimped on properly
4 cracks welded up in the frame
New idler link in the bucket arms
New bushings installed in the arms, bucket, and me thinks some of the cylinders
New voltmeter
Engine shut off cable repaired
Cracks in the bucket welded up
Idler wheel repaired and bolted back on
Air filter replaced
New exhaust stack installed (Yup, the chrome is gone!)
New Hydraulic fluid
Tracks adjusted
Same ugly paint
I get to steam clean it this coming week
Did I mention same ugly paint??
I want to paint it OD Green before it leaves the shop, but the Case guys are a bit stand offish everytime I start in talking about spraying color next to all their expensive machines...
If it all goes well, I'll have it trucked down to the farm this week some time, and stick it under a tarp

As for the barn. the builder told me he couldn't get out to my place with that road in the condition it is in now. So job 1 is to fix the road, then I can get started on the barn.
That is to be a 36 X 56 two story affair. 10" concrete floor 16' walls with a 8/12 pitch roof and a cozy apartment tucked up there. It will have a glass cupola upstairs hear and air, a second floor deck a septic and a cistern. I'll put a small covered deck with rocking chairs down below and gravel around one side and put grapes and fruit trees around the other sides to keep me from running Big Red all over the tile field.
I would like to have the barn done minus the apartment by mid summer, then able to live in by thanksgiving next year.
I am thinking of having a gathering down there this summer...more on that soon if my concept works out...you'll like that!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 08:30:52 PM
I didn't get to plug away on the bumper project but I did get a bunch of cool stuff in for it, enough to almost finish it off.
Here are the over-center latches I found on line. I purchased these latches for a little over $8 each! I found them selling in other places for anywhere from 30's upward into the 70's each! I picked these up from Sears! Yea, Sears, so I bought extra ones for future needs.
(http://i.imgur.com/YFGGXJd.jpg)
(http://i.imgur.com/uygzVy0.jpg)

It will fit onto the main beam and bumper in approximately the following manner:
(http://i.imgur.com/rI9mVN4.jpg)
(http://i.imgur.com/KSBYVDo.jpg)
(http://i.imgur.com/RntvFgo.jpg)
(http://i.imgur.com/CE54Yvh.jpg)

Once the tire flange axle is trimmed to size, it will be held in place by 3 pinch bolts, 1/2" and fine thread thank you very much! The idea here is if I ever need to rotate or reposition the axle, perhaps because of larger tires or different back space wheels, then all I'll have to do is remove an inch of rust, then heat the rusty mess, use penetrating oil and finally strip the heads off and give up on the whole idea. In reality all I'd like to do would be to loosen and rotate, but we all know that is much too easy to expect it will ever happen!
(http://i.imgur.com/DwbgvNg.jpg)
(http://i.imgur.com/8EEpYzb.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 15, 2014, 08:32:50 PM
The project has been going along much too well, so I decided to weld in the wheel studs all crooked
I think I succeeded!
(http://i.imgur.com/3AGu3jb.jpg)

Well, maybe I didn't weld anything yet, who knows, but hey here's some neat parts that I ordered that showed up
The plastic guards fit into the clevis's and make them all pretty. Not sure what else they do, but I'm good with the splash of color with the extra torque and horsepower that provides!
The packages are Israeli battle bandages and let me tell you, if you don't have some, GET THEM. Get one for practice and a half dozen or so to pack away. THe band aid looking things are steri-strips for gluing body parts (as in human) back together when something you didn't plan for comes your way. Those were added to my field medical kit stored in the back.
The black rubber looking things are black rubber things!
I kind of like them so I bought them. I might use them or I might store them to be forgotten and sold in 10 years at some future garage sale. But for now I have them and know where they are. I think they lock stuff like axe handles in place...
(http://i.imgur.com/UTtDYJx.jpg)
(http://i.imgur.com/4V0ckrc.jpg)
(http://i.imgur.com/pOzJcE8.jpg)
(http://i.imgur.com/VHzv9eH.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:16:19 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:18:10 PM
OK, into day 10 of the bumper build with tonight's posts. With the exception of possibly adding a Hi-Lift jack mount to all this, and a locking device for the fuel cans, the fabrication is complete.
Today's objective was to finish the tire carrier which was completed and to add the secondary over center clamp to the main beam, which is also complete.
I welded the three nuts onto the spare mount which will retain the tire axle:
(http://i.imgur.com/5BPDE9i.jpg)
(http://i.imgur.com/UNYyTtT.jpg)

Next, using the spare as a guide, the wheel studs were welded onto the flange providing for a secure base to bolt the spare wheel onto:
(http://i.imgur.com/kqHTi18.jpg)
(http://i.imgur.com/N7Uu5bg.jpg)

Next up was the creation of a mount for the secondary over-center latch.
Placing the cardboard welding table into service yet again, and starting with a cardboard model, I cut out the first few pieces from 12 gage steel sheet:
(http://i.imgur.com/pF9boGX.jpg)
(http://i.imgur.com/kLbguAE.jpg)
(http://i.imgur.com/UclmSaV.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:22:40 PM
Lining up the latch base in the same plane of the bumper strike plate took some juggling, but with a little luck of the Irish, we made the first of many tack welds:
(http://i.imgur.com/9fhkhIn.jpg)

Then all the assundry pieces were cut with the plasma cutter, ground and tacked into place. I was not as concerned for absolute percision as the intent was to weld it together from the inside, then grind all the overhang away, which I did.
(http://i.imgur.com/G7cS16b.jpg)
(http://i.imgur.com/YaXkH19.jpg)
(http://i.imgur.com/jbewdpT.jpg)
(http://i.imgur.com/pJNPcnd.jpg)

...And resulting in this odd shaped box:
(http://i.imgur.com/l2xSm5S.jpg)
(http://i.imgur.com/aODi6a2.jpg)

After welding and the initial grinding, this is what resulted, which was welded onto the main beam.
(http://i.imgur.com/FLQWByX.jpg)
(http://i.imgur.com/m9Rl4it.jpg)

The earlier photo shows some gaps, but they were filed in with weld, then ground flat. The fit was good and strong.
The latch catch went in first with some drilling and tapping for 5/16 coarse thread screws. I chose allen head stainless.
(http://i.imgur.com/pyyUhrn.jpg)
(http://i.imgur.com/kvO7cSb.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:24:36 PM
Next the latch mount box was also drilled and tapped, then final welded onto the main beam.
(http://i.imgur.com/JvKkaGf.jpg)
(http://i.imgur.com/5BIyoY4.jpg)
(http://i.imgur.com/fvzWSCZ.jpg)

Once it was secured I adjusted the latch to pull the beam in against the poly vibration pad. I immediately noticed that when I closed the latch it tends to pull the beam more upright against the torsional stress of all that junk hanging off to the rear!
(http://i.imgur.com/vGdla1O.jpg)
(http://i.imgur.com/DM13YdT.jpg)
(http://i.imgur.com/cUtpr75.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:26:52 PM
I'll start the cosmetic prep tomorrow. I'd like to do some more grinding, then coat the thing with body filler and sand smooth prior to finishing to give it a better appearance.
I'll figure out some way to secure the cans with a lock and move this whole thing toward paint, which is what I have decided to do.
The wheel and tire are on order and will be here in days, so this should (might) come together this week!
Well, that is if I don't need to move Big Red on Friday.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:27:54 PM
.....Quote:
Originally Posted by C************
"You got me intrigued.. explain the new ic pipe you hinted at.. lol "


Myself and another member have custom passenger IC pipes being built. Actually, I believe mine, the prototype is already done.
This is a new system that goes all the way from the IC to the Y-Bridge. It eliminates the EGR air valve and heater grid completely. So there should be an improvement in flow and certainly more clutter. Gone is the cumbersome plastic up pipe and that funky connector. The air valve, heater grid, cable and mount all goes bye-bye and another 3" Mandrel bent pipe goes over to the factory Y-bridge stand. Simple clean, coated and 3" all the way.
I had mine made with a couple of 1/8" NPT bosses for H20/Methanol injection, but the pipe can be made either way.
You will, of course have to delete that awful EGR, but with having done so, this mighty LML is getting better parts and cleaner all the time.
Next up will be a replacement Y-bridge that actually necks down from 3" to something less than 2.5" and has an awful bend in it.
I'll check with the man and if it's OK, I'll release his name so everyone else can order.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:29:52 PM
Quote:
Originally Posted by C*************
"Is that being made by the guy at t-rex? We had a similar convo earlier today "

Yes, Calvin.
I had just emailed him to ask his permission to release his name, but it seems you are talking to him as well.
I chatted to him about making a full delete pipe. He agreed, I sent some rudimentary measurements and away we went. He said he had it done I believe and would ship it this week. I'll install it next week and figure out what to take off and where, and get all that figured out.



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:32:26 PM
OK, after evaluating the need for a main beam stop to limit travel, I decided against it. The tire will come to rest against the body so that is a pretty natural stop in itself. My Hummer was the same way, and it worked fine.

So after running around and buying the paint and spray gun I got started grinding which I did for over an hour. THen came the wire cup brush for some more detail cleaning.
After all that, I cleanec out the inside of the bumper and sprayed it with U-Pol acid etching primer.
(http://i.imgur.com/2xCFGsg.jpg)
(http://i.imgur.com/SajbwUi.jpg)
(http://i.imgur.com/Jsvf9M1.jpg)

I only have siphon hi pressure spray guns so I upgraded to a HVLP gravity gun compliments of Lowes
I will be spraying a variety of products depending on the particuliar area on this bumper, but the main coating will be the John Deere obtained Ditzler satin black using hardener.
(http://i.imgur.com/XxriY1Z.jpg)
(http://i.imgur.com/qwmQmYP.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:35:26 PM
You know I said Ditzler, but it's Valspar, my bad!

Next I filled in around the welds with body filler working it into all the imperfections. I thought about painting over the welds, exposing them, but I finally decided to smooth everything up somewhat to make a better looking finished product.
(http://i.imgur.com/1lsQWvq.jpg)
(http://i.imgur.com/ztoFdDj.jpg)
(http://i.imgur.com/27OJRKd.jpg)
(http://i.imgur.com/WfBIRRb.jpg)
(http://i.imgur.com/wa5mE1M.jpg)

Quote:
Originally Posted by Dustoff 35
"Good call on covering up those welds !!! "

Man you should give me a little credit for the three decent welds on there!

Hey, you should see Big Red now. I spent hours with a steam cleaner spraying hot soapy water on it. I went through a lot of the soap that the boys at Case generously allowed me to use. It is still butt ugly, but one heck of a lot cleaner. And minus square yards of grease streaks and smears!

Now, back to sanding!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:38:02 PM
Just a little got completed today.
I spent hours steam cleaning Big Red so no sanding my fingerprints off!

But what I did get done, focusing on the tire carrier made a significant difference:
(http://i.imgur.com/Tdgi5JV.jpg)
(http://i.imgur.com/fa6cKLY.jpg)
(http://i.imgur.com/1jE3k18.jpg)
(http://i.imgur.com/8TkbUgO.jpg)

Those joints will need one more thin coat of plastic filler to make all things right with the world, but you can see they did get most of the way there with the initial fill.
I'll plug away at it in the morrow and see if I can make some more of this look like it is one piece.
(http://i.imgur.com/vFqJEsi.jpg)
(http://i.imgur.com/NqGHw2s.jpg)
(http://i.imgur.com/roJpQYm.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:44:06 PM
All the sanding and smoothing of the plastic is a slow, labor intensive process. I am not going for perfection just a smoothing of the contours and weld joints. Never the less. I am approaching 8 hours of grinding, painting, working body filler and staring. Probably more of the latter!

So I got the final coat of body filler on the tire carrier and got the can carrier in primer after much sanding and a total loss of useable fingerprints!
Here's where tire carrier is at the moment:
(http://i.imgur.com/yWPID1D.jpg)

After beaucoup sanding with all sorts of devices, this is what the car holder looked like prior to primer:
(http://i.imgur.com/l6cfVAe.jpg)
(http://i.imgur.com/yDKYw8h.jpg)
(http://i.imgur.com/IRnnaye.jpg)
(http://i.imgur.com/9hWhXqG.jpg)

Then after the acid etch primer:
(http://i.imgur.com/H79UKWM.jpg)
(http://i.imgur.com/KPbKAn5.jpg)

And a couple more, however I really just wanted to get the primer on there to prevent any rust. I still have to fab up a can rack which will be simple and require just a little welding. I'll clean off that area with the wire brush, then repaint after I am finished.
(http://i.imgur.com/iecZql3.jpg)
(http://i.imgur.com/GHcTw4I.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:49:18 PM
Thanks!
It will hopefully look like it's attached to the truck before next year!

Made some progress today on the locking/retention device for the fuel and water can rack.

I want the cans to be postively retained with no rattling around like was the case on my old main battle tank back in the day. So I decided to incorporate dense foam padding into the design from the beginning. Starting with an ancient coleman ground mat which the dogs partially chewed up, I cut a strip. This piece is only for fitting the soon to come bracket.
(http://i.imgur.com/FwjGl9h.jpg)
(http://i.imgur.com/mcmDIxg.jpg)

I decided to use 4" wide 1/8" mild steel to hold everything in place. The idea is to make a flexible belt as it were from the plate. I did that by shaping the steel and welding sturdy hinges to it.

This first piece will eventually weld to the side of the can holder and be hinged so it can easily fold out of the way.
(http://i.imgur.com/SlvFZki.jpg)

Here the side piece is going together
(http://i.imgur.com/SV7hjrW.jpg)
(http://i.imgur.com/LYvgGJJ.jpg)
(http://i.imgur.com/e6TvW7l.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:51:53 PM
In this series the top piece is cut, fitted, and welded to the side piece hinge
(http://i.imgur.com/IcNziRC.jpg)
(http://i.imgur.com/vMz0aMb.jpg)
(http://i.imgur.com/iHVxvSN.jpg)
(http://i.imgur.com/9QpF4Ss.jpg)

Some more angles of the top section construction
(http://i.imgur.com/VYD2w27.jpg)
(http://i.imgur.com/gmIfGMu.jpg)

Hmmm, got a fuzzy one...rare find, I wonder if it's worth anything???

OK moving to the side, I first had to fab up a striker plate and latch holder. Here it gets done:
(http://i.imgur.com/KGXBzwn.jpg)
(http://i.imgur.com/UQYb4gU.jpg)
(http://i.imgur.com/Q32cUrd.jpg)
(http://i.imgur.com/g7Fncjo.jpg)
(http://i.imgur.com/ZBDKrFO.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:56:13 PM
Next comes the side plate which I bent to tend to squeeze the cans together as you pulled it down to the latch.
(http://i.imgur.com/OLvJxOp.jpg)
(http://i.imgur.com/UENm0Iv.jpg)
(http://i.imgur.com/PzKybjV.jpg)

Here's the flexi-strap thingy before I permanized it
(http://i.imgur.com/S6TCIVO.jpg)
(http://i.imgur.com/J5eV4nR.jpg)

Then I welded the upper catch and drilled 4 holes for the handy-dandy over-center latch and attached it to the rack
(http://i.imgur.com/rc6hpA0.jpg)
(http://i.imgur.com/fKwEQko.jpg)
(http://i.imgur.com/RwNcKpx.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 10:57:22 PM
Utilizing a simple shock tab, I welded it inbetween the catch and the latch so that when the lock is closed in place, you can't lift the handle far enough to open the thing. A determined thief could get through it, but a casual passer-by hoping to score a gas can will not be able to easily snag anything.
(http://i.imgur.com/JuvNrS8.jpg)
(http://i.imgur.com/A7BakEM.jpg)
(http://i.imgur.com/8MLhRoM.jpg)
(http://i.imgur.com/fhzzCfA.jpg)

Just to be sure, I plan to extend the catch "hook" area about half an inch with some additional hardware and welding. Minus painting and gluing on of the foam pads, this project is in the bag. Now on to more finishing and finding a place for the hi-lift jack.
Travis, sorry for adding so much to your bumper, but I sort of warned you it was headed in this direction! 


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 11:02:01 PM
This was day 15 of the bumper build project.
I'm in a laborous stage of the bumper finishing. The work is tedious and has to be done over and over again until the desired result is achieved. Conversly, if I rush through this part, I will end up with a questionable end product which is not at all in keeping with the execllent product Road Armor supplied.
So with the few hours I had today, I just pushed the ball down field a few more yards.
Initially, after looking at the anchor side of the can retainer, I didn't like the angle. It was straight, whereas, it should have tapered in toward the cans a bit. So I corrected that.
(http://i.imgur.com/k6cI2Np.jpg)
(http://i.imgur.com/bwk5Bmy.jpg)

There was some minor cutting and welding involved, so I pulled some body filler over the piece after I ground the welds flush

Next up, I worked all the body filler covered welds on the tire carrier. After I had them smooth I sprayed it once again with the acid etching primer.
(http://i.imgur.com/Bb9JG72.jpg)
(http://i.imgur.com/TWPL8Z7.jpg)
(http://i.imgur.com/E9Xlh1C.jpg)

Most of it now is satisfactory for finishing, however on close inspection some bad spots showed up again. Sometimes you just can't see what it looks like until you get it primed up. These areas will get another coat of plastic and more sanding:
(http://i.imgur.com/rhqZKo1.jpg)

I guess I missed sanding that spot all together, but I know about it now!

I ground down some more welds and coated them as well. I am starting to run out of areas to work on the bumper which is a good thing!
(http://i.imgur.com/p7iHn68.jpg)
(http://i.imgur.com/1blPlXe.jpg)
(http://i.imgur.com/Lh6Ml5t.jpg)

(http://i.imgur.com/Lh6Ml5t.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 11:03:02 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 16, 2014, 11:06:49 PM
                                                                          (4106)
Coming up on paint!
I put a marathon day in on the finishing of all the welds, this's and that's that still needed to get done. Well I got them done, so in the morrow we'll be seein paint!
I finished the body filler, as much as I am going to do, recognizing this is a bumper and not a show car.
Here's some of the progress photos today:
(http://i.imgur.com/P3hINmq.jpg)
(http://i.imgur.com/7FynkvD.jpg)
(http://i.imgur.com/0opFCll.jpg)

It's all starting to look rather integrated and more and more of the thing was coated with the acid etching primer
(http://i.imgur.com/bWiIMD8.jpg)
(http://i.imgur.com/5jFHoH8.jpg)
(http://i.imgur.com/IU99U9u.jpg)

After spraying the bump stop with the primer, I wasn't liking that weld so much so I let it dry and hit it with a disc sander and a 100 grit pad. It did a remarkable job on it making it smooth and rounded. It didn't need any filler!
I moved on to some other parts:
(http://i.imgur.com/wMsbfr1.jpg)
(http://i.imgur.com/2nVxbAn.jpg)
(http://i.imgur.com/ybHkWgx.jpg)
(http://i.imgur.com/OBwovyh.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 08:43:07 PM
In that last photo you may notice I extended the latch catch for the fuel can retainer about an inch. It is much more positive now.
Here's some more progress:
(http://i.imgur.com/x22u9SG.jpg)
(http://i.imgur.com/A3QqnsT.jpg)

The yellow paint is zinc phosphate a self sactificing zinc based material used in aircraft construction. I sprayed it on the suspected high corrosion areas
(http://i.imgur.com/xfKJE6A.jpg)
(http://i.imgur.com/z0h1dPN.jpg)
(http://i.imgur.com/3mxTLuf.jpg)
(http://i.imgur.com/m9dGWmg.jpg)

Yep, there are a few runs, but just think of those as extra thick protection
I also refinished that wheel mount. It looks much better now
(http://i.imgur.com/wYQn7Sv.jpg)

I actually worked on the bumper 15 minutes and cleaned up and put things away for 7 hours. Well, it seemed that way!
I am obviously still not done cleaning, but that will happen prior to spraying paint tomorrow.
That cardboard welding table worked out pretty well!
(http://i.imgur.com/q5tSz9M.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 08:48:28 PM
Quote:
Originally Posted by j***********
"i forgot if i saw it or not but will the tailgate still be attached or not? and if it will be, will it be able to open and lay down with that fancy metal work on the back end? (mainly the part attached to the rear bumper on the passenger side) "

Reading this post gave one of those "HOLY CRAP" moments. You know like you build a room addition and just before you get ready to move in, realize you forgot to add outlets...Not saying I ever did something like that, but, well...

So I reinspected the whole thing and yes, I am good to go. The main beam pedestal is indeed outside of the area of the tail gate swing!
But in looking at it, I suddenly decided I don't like those triangular steel stops. So tomorrow I am going to intro them to Mr. saw and let them discuss things for awhile!

So today I pressed forward on the painting. It literally took a couple hours of cleaning and vacuuming to get that part of the garage dust free enough to attempt spraying some finish.
One big surprise was I have another table! Yes, directly beneath the cardboard welding table I discovered a wooden painting table! Can you imagine my surprise! What luck!
So with the proper moment of silence for the removal of the cardboard which had taken many burns, although never burst into flame. I moved on...
The wooden painting table is not as complete, it seems to have come as a bunch of wooden slats nailed haphazardly to some poor quality wood with some bent and crooked nails. But the thing seems to be holding out so I let the painting begin.
I got everything primed and in some cases following with some more sanding grinding and contouring. The end result looks good enough to put in the spouse's fine china cabinet!
What do you think?
(http://i.imgur.com/dbT8aEv.jpg)
(http://i.imgur.com/25CGIjs.jpg)
(http://i.imgur.com/kOBAaJ2.jpg)

Actually if the truth be known, I sprayed the bottom of the tire carrier assembly beam first, then finished priming the bumper. so that's how I'll show it here:
(http://i.imgur.com/NJlDyFl.jpg)
(http://i.imgur.com/0QoilG2.jpg)
(http://i.imgur.com/BYFu3fz.jpg)
(http://i.imgur.com/lcRNB2X.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 08:53:07 PM
You can already see the top part mostly sprayed, here's what I used:
(http://i.imgur.com/8hhZaom.jpg)

This material is a high quality poly plastic coating that sprays on in the same manner as rubberized undercoating, however dries to a bed liner consistiency and hardness. One can did all this:
(http://i.imgur.com/7mnjZsa.jpg)
(http://i.imgur.com/3ldxikX.jpg)
(http://i.imgur.com/yBNDTFX.jpg)
(http://i.imgur.com/eAJO2nH.jpg)

Basically we're looking at the bottom and outside edges, an area I'd equate to maybe 65%-75% of the total area. The concept was to spray this in the morning (check) then allow it to dry for 24 hours, then in the morrow, flip that sucker like some sumo wrestler going for half gallon of ice cream in a syclone! Then proceed with spraying the rest of it and giving a double coating to the areas where stuff might rub.
I'll also spray the inside of the bumper with the bed liner because it will take some abuse with flying pebbles from the dusty areas of the mall, and of course, should I attempt to cross one of those dreaded mulch beds, no telling what kind of damage that bumper will have to contend with! Better be safe than sorry, we all know the type and amount of damage dust and mulch can reap upon our fragile trucks!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 08:57:32 PM
I picked up the spare today. Same Pro comp wheel as before and almost the same Toyo MT as before, but this tire was specially created with reformulated rubber. THis particuliar rubber actually has finely ground mulch dust added to the mixture. The idea is that the mulch imbedded in the tire will be able to stick to the mulch in those nasty flower beds around the mall, and I might get enough traction where I no longer get stuck in them! Also, since I have gotten a greener attitude and even recently sold all my "Nuke the Whales" T-shirts, I decided these tires ought to decay all by themselves. I figure when the tires wear out, in true Kintucky style, I'll fill them with dirt, stick a plant in them at the end of the driveway and they will decompose into a nice rounded plant bed in three to four hundred years! Good thinking eh?
(http://i.imgur.com/h9yEMwa.jpg)
(http://i.imgur.com/2WuVHqk.jpg)

I almost got it done today, but I'll have to spray the actual bumper exterior tomorrow.
Today I finished with the bed liner coating and got everything done right up to paint.
Here's how it progressed:
(http://i.imgur.com/JQ8LyOx.jpg)
(http://i.imgur.com/usFYvGH.jpg)
(http://i.imgur.com/tY9Jp8i.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:00:11 PM
The yellow zinc phosphate provided a good contrast to show areas I missed. Here things are getting done:
(http://i.imgur.com/LU5rUNb.jpg)
(http://i.imgur.com/VdfEdh3.jpg)
(http://i.imgur.com/ytjwh93.jpg)

As planned, I coated the inside of the bumper, the side which I think would be subject to the most abuse
(http://i.imgur.com/HNyRKUz.jpg)
(http://i.imgur.com/FM5zXd1.jpg)
(http://i.imgur.com/J9CNuGV.jpg)

And the spare tire hub:
(http://i.imgur.com/DIhFiDD.jpg)

It came out about how I envisioned it would
(http://i.imgur.com/Euu3XK7.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:04:02 PM
One final chore was drilling the holes for the lisence plate mount, which I will temporarily install, pending a possible future rear winch install
With the holes drilled, the bumper is just about ready for the final coat of paint.
(http://i.imgur.com/FolSBAX.jpg)
(http://i.imgur.com/kBmhdpr.jpg)
(http://i.imgur.com/QB9TTCu.jpg)

moving along on the bumper build thread with 400 extra pages attached!
I just sprayed coat #3 of the John Deere blitz black paint and gun lube. I used dealer recommended products and a new Lowes sourced HVLP spray gun which did a flat great job of laying down that paint!
(http://i.imgur.com/FVs3pe2.jpg)
(http://i.imgur.com/9PV8qFV.jpg)
(http://i.imgur.com/8XulNtr.jpg)
(http://i.imgur.com/YpPuzEe.jpg)

The calculations there are my conversions from ratios to inches. I created this highly specialized screwdriver paint mixing system and porportion determining thing, well, that's all technical. I used this thing to add the paint, thinner and hardener in together:
(http://i.imgur.com/868H2eq.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:07:28 PM
Here's the first wet coat going on
(http://i.imgur.com/zkYc5V5.jpg)
(http://i.imgur.com/xv8rSM6.jpg)
(http://i.imgur.com/5oLFi5Y.jpg)

And after 15 minutes drying time:
(http://i.imgur.com/40nr16L.jpg)
(http://i.imgur.com/Kf4tuwQ.jpg)

I applied a second and a third coat of paint with 15-20 minutes set up time between each coat. Here's various shots of that process:
(http://i.imgur.com/ZtGsI5L.jpg)
(http://i.imgur.com/wbfaP1m.jpg)
(http://i.imgur.com/aRygOpo.jpg)
(http://i.imgur.com/k1tonVK.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:08:30 PM
And after the last coat, the contrast between the bedliner coated upper and the painted lower portions of this expedition bumper. THe paint is still wet in these shots, hence shiney, which it has already ceased to be.
(http://i.imgur.com/bF7Zfzo.jpg)
(http://i.imgur.com/KUsXBaX.jpg)
(http://i.imgur.com/u8Quego.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:09:00 PM
Well, I think that gets me to the installation of this 3-week long modification of the very excellent new for our trucks rear bumper where it became a very capable expedition bumper capable of supporting all sorts of cool stuff. Now if it only fits and doesn't fall apart!!!!!!!!!!!!!!!!!!!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:13:09 PM
I had planned to install the bumper tomorrow. So this afternoon, I removed the stocker to get ready for the swap.
It would be a fairly easy proposition to remove the stocker, that is if you don't have sulastic shackles. If you do, then you have a nightmare and migrane to contend with. Guess which path I had to go down.
Yea...
You see the three bolts which hold the factory bracket are completely covered with that big knob of steel and rubber. So either you get scotty to dissemble it with a transporter or you get to take off the shackle, at least part of the way. Then you get to jack the truck up to loosen this one, then lower it all the way to get the other one, then wiggle it somewhere in between to get the third.
So here's the process
(http://i.imgur.com/KqhJoCN.jpg)
(http://i.imgur.com/shFEChG.jpg)
(http://i.imgur.com/4kFEiwz.jpg)
(http://i.imgur.com/pfOQGqL.jpg)

The plastic unsnaps and is pryed off. The lisence plate light unplugs as do the Back up sensors
(http://i.imgur.com/enodPF7.jpg)
(http://i.imgur.com/Xb4mkbx.jpg)
(http://i.imgur.com/zNVWZRs.jpg)
(http://i.imgur.com/3Pecwle.jpg)

This is where the Abb workout started. You can see how the sulastic shackle covers over the bolt head. There isn't even enough room for a wrench!
(http://i.imgur.com/I4hb26g.jpg)
(http://i.imgur.com/BeomesE.jpg)
(http://i.imgur.com/LUHDgSW.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:17:03 PM
That was my finger in the last pic before I smashed it, but that's another story...
You have to look, but in the last two shots I am bending the steel in the bumper substantially with just my hand!
The main truss is pretty thin, in fact the wax coating is thicker than the steel. I'd say you don't have much protection back there!
(http://i.imgur.com/Igj3bgM.jpg)
(http://i.imgur.com/jVSjdTx.jpg)
(http://i.imgur.com/MjdxkLm.jpg)
(http://i.imgur.com/q5Degzf.jpg)

This plastic spacer was mounted on the rop at each corner, so I pryed it away to get more working room
The bolts holding the bumper to the frame and to the hitch were pretty big, having a 21mm bolt head.
(http://i.imgur.com/F05upeD.jpg)
(http://i.imgur.com/0ffFc4Z.jpg)
(http://i.imgur.com/JNY8nkL.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:21:06 PM
The electrical connectors were all in one location and just pop apart
(http://i.imgur.com/BnuDAGG.jpg)
(http://i.imgur.com/ApFSqtm.jpg)
(http://i.imgur.com/SWZWxsv.jpg)
(http://i.imgur.com/HGBgzJh.jpg)

Finally the bumper yielded and came off. Here's what it looks like at the moment:
(http://i.imgur.com/Q1iEWyG.jpg)
(http://i.imgur.com/8EWxMub.png)
(http://i.imgur.com/oWL8eyy.jpg)
(http://i.imgur.com/ZlnfXbs.jpg)

Here's the parts outside where the dog can chew on them some prior to installation to give them that trail scratched look
(http://i.imgur.com/fBVvzwq.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:26:09 PM
Here's where it got interesting.
Ever heard that famous phrase, Houston, we have a problem?
Well, I have a fitment issue it would appear:
(http://i.imgur.com/gG4kKi8.jpg)

It's a lot more complicated than just these holes not lining up.
First I will need to cut some slots into the body flange there. OK, no big deal, but if I do then that bracket will get pretty close to the bottom of the tailgate.
That wouldn't be an issue except the bracket does not fit near the top of the bumper, but perhaps 1"-1.5" below the top edge. So if I mounted it all up that way, then the tailgate would not open without striking the bumper on the downward arc somewhere.
So I'm thinking if that happens then obviously the bumper is in the wrong place, so will it even bolt up to the trailer hitch?
Well, tomorrow will tell the tale. Right now I'm kind of emotionally beat. If this thing can't be made to fit, well...
(http://i.imgur.com/XSPkbvY.jpg)

Quote:
Originally Posted by S*********
"You will find a way!! Im sure if all else fails you will fabricate your own mounts."


You just gave me an idea!
If I cut the factory brackets off the bumper I just took off, and then cut that end off of the Road Armor bumper, I should be able to weld the two pieces together and get it done!
Yea, that's the ticket!

Quote:
Originally Posted by k***********
"My first post in this thread after completing all 418 pages. Absolutely awesome. Great read and great information. I can definitely thank Don for all this has become and also being a TRUE PATRIOT. But to address the bumper fitment, I have some experience with you're issue being a bodyman by trade. I would have assumed that Road Armor would have known this but when they has it mounted on a half ton it wouldn't fit a 3/4 ton. Taller frame which puts the bolt holes in a higher position. Basically if you ordered a brand new stock bumper, everything would swap between trucks besides the actual brackets"


I basically have the two options I already mentioned. Cut a slot in the body flange and fit the RA bracket, but like you said, that places everything too high. So option 2 would be to reuse the stock horns, bolted in place, then cut into the RA brackets and figure how to splice the two together. Should be a half day project, worst case, and barring anymore discoveries.
Anyone know if the 1/2 ton and 3/4 ton hitches have the same approximate dimensions? I'm thinking I just might get lucky with that one since I believe both trucks use the same rear bumper.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:32:50 PM
Quote:
Originally Posted by nmeyer414
"Off hand don, have you called your guy @ RA to see what he says? "

Sure did, emailed actually. Travis was all over it. He offered a different bracket which also fits the 2008 1500 silvy. He explained there were many variations to the chevy truck frame which he has to cope with.

The good news is, I solved the problem as we will see over the next few posts.
I started with prepping everything with tape to prevent accidental scratching.
(http://i.imgur.com/LJLSyDj.jpg)
(http://i.imgur.com/93zw8Nh.jpg)
(http://i.imgur.com/rjC1soS.jpg)

The next step in the process was to mount the bumper to the trailer hitch using two large bolts, then begin the process of reverse engineering the brackets
(http://i.imgur.com/5HIL9Vh.jpg)
(http://i.imgur.com/dzgc1QG.jpg)
(http://i.imgur.com/38eZl7X.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:38:14 PM
OK, so far, so good. I had a decent dimentional fit. while holding my breath, after prayer, and a wispered, "Come on, FIT!" I slowly opened the tailgate. Did I measure correctly? A tad off and the tailgate would have to go bye-bye!

What do you think?
(http://i.imgur.com/laXLwFk.jpg)
(http://i.imgur.com/AfU1k3D.jpg)
(http://i.imgur.com/7jmH83R.jpg)
(http://i.imgur.com/yHLccaB.jpg)

That worked out nice! There is an even 1/4" gap between the boss which the main beam rests on and the tailgate...Good to go!

Without adjusting anything yet, see how well this bumper sucks into the body work?
NICE JOB TRAVIS!!!!!
(http://i.imgur.com/kR8sCmr.jpg)

Knowing I'd have to use the factory brackets, I first removed the structural piece from the bumper, then cut off the brackets.
Notice how much protection you don't have. THe bumper skin is super thin. I could bend it with my hand. The assembly only weighed a couple pounds without the one thicker beam which is the skinny little piece. I tell you there is nothing there...Just like the front bumper!
(http://i.imgur.com/G7IoFDS.jpg)
(http://i.imgur.com/FviMMg6.jpg)
(http://i.imgur.com/PFSbvAT.jpg)
(http://i.imgur.com/TTnVjGC.jpg)

The Road Armor brackets would have to be cut to fit. So after squeezing them in there I marked and cut them.
(http://i.imgur.com/e7IUpuS.jpg)
(http://i.imgur.com/ediNDjI.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:41:00 PM
After some fine tuning, I ground the mating surfaces down on all 4 pieces, then drilled a dozen holes randomly in all parts. THe idea would be to bolt the halves up to the frame and bumper, then weld through a hole, forming a rose weld, then remove the part and finish weld it.
(http://i.imgur.com/rFvQahM.jpg)
(http://i.imgur.com/iv4Mqvl.jpg)
(http://i.imgur.com/PC0luXP.jpg)
(http://i.imgur.com/GAtf2j6.jpg)

Here the brackets are tacked together, then removed and welded, then brushed and painted, then reinstalled right before your very eyes!
(http://i.imgur.com/kzmu951.jpg)
(http://i.imgur.com/VX3RDev.jpg)
(http://i.imgur.com/9fCvQ7B.jpg)

Next, I transferred the back up sensors and wiring harness to the Road Armor bumper. The sensors are indexed with a fitting that fits one way only into grooves cut into the RA bumper surface
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:44:46 PM
Without further adieu, I placed the bumper onto the hitch for the last time. THe studs in the bumper fell right into the bracket holes!
(http://i.imgur.com/c5NygUZ.jpg)
(http://i.imgur.com/X1JXAwr.jpg)
(http://i.imgur.com/CtF0EnX.jpg)
(http://i.imgur.com/AMqefM7.jpg)

The brackets fit well and offered all the adjustment I needed.
Using two .75" thick blocks of wood, I jacked the bumper up against the bottom of the tailgate and tightened the bolts. I had removed the tape earlier so that I could get some good measurements and eyeball alignment. It fell right in with no fuss at all!
(http://i.imgur.com/sZewDiV.jpg)
(http://i.imgur.com/P7e0nvT.jpg)

Here it is in it's current state. All bolts are tightened and adjustments made. The fit is exceptional, I think. My hat's off to Travis at Road Armor bor creating a magnificent piece!
(http://i.imgur.com/A5eZaGj.jpg)
(http://i.imgur.com/9nsuyg7.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:50:40 PM
Quote:
Originally Posted by G***********
"Looking really good. You should paint the two back up sensors that are silver to blend in with the other two and the bumper. Looking forward to seeing that rack on there too ! "

I don't think I am going to paint them at all. Not sure what effect a layer of paint might have on the sensor. I have experience in that area with regard to aircraft radar, FLIR, and other sensors. You can't paint them!

As for waiting for the rack, wait no more. I got it on today, although it fought me for hours. What I thought was going to be a 2 hour deal lasted from 1000 until 1700!

Here's how it shaped up:

I gave the hardware a coat or two of SHark Hide to allow drying time prior to installation .
(http://i.imgur.com/dCBzobc.jpg)
(http://i.imgur.com/SZ6ITRE.jpg)
(http://i.imgur.com/D7P1oS9.jpg)

Next I installed the trailer harness and reattached the aft wiring harness
(http://i.imgur.com/SduQlXG.jpg)
(http://i.imgur.com/MVhl4vv.jpg)
(http://i.imgur.com/acz2DXN.jpg)
(http://i.imgur.com/9lSzAH5.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:52:13 PM
More of that sequence
(http://i.imgur.com/tGW5hLb.jpg)
(http://i.imgur.com/UJ94kjy.jpg)

Then the hardware went on along with the latches and that's when I noticed the thing was leaning aft!
So after loosening up the bumper bolts again and realigning the bumper, I tightened down the bolts and called it a day.
There wasn't enough time remaining to mount up the tire, so this will stretch out another day!


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:59:32 PM
OK, was away for a few hours, but just got back.
I took some photos of the tire rack without the spare like it is at the moment.
The photos are a bit dark but you get the idea:
(http://i.imgur.com/Lu2IHKU.jpg)
(http://i.imgur.com/vQP1bYB.jpg)
(http://i.imgur.com/RSoF0dI.jpg)
(http://i.imgur.com/JUIny7B.jpg)
(http://i.imgur.com/0X5nVW8.jpg)
(http://i.imgur.com/ldJI7Dz.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 09:59:48 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:02:58 PM
Well, I said I didn't have tire pics to post tonight...the tractor won't start so I have no way of lifting that thing onto the rack, especially considering the little rangers are covered up with homework without a second to spare!

But I didn't say I wouldn't post some pics!
Here's some teaser shots of the experimental T-Rex passenger IC pipe that eliminates the butterfly valve and heater and a bunch of other crap:
(http://i.imgur.com/hdsostS.jpg)
(http://i.imgur.com/Ym1RRWE.jpg)
(http://i.imgur.com/zOnN8JW.jpg)
(http://i.imgur.com/aG7nkbq.jpg)

Now all I can gurantee is that the pipe will be installed.
I will not gurantee that it will work, however.
Not saying Calvin at T-Rex did anything wrong, just saying that I requested this be done as an experimental design. Seems about two other guys here had the same idea at about the same time and have ordered their own pipes as well. So someone will get one of these pipes bolted on PDQ and get the general civie public some information in the not too distant future

Some more pics:
(http://i.imgur.com/aG7nkbq.jpg)
(http://i.imgur.com/VF9mlGN.jpg)
(http://i.imgur.com/Lz1nIzd.jpg)
(http://i.imgur.com/gGwPrOf.jpg)
(http://i.imgur.com/0qxbjWS.jpg)
(http://i.imgur.com/5vDHlmw.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:07:32 PM
OK, tonight I can put this project in the can. I test fit, adjusted then mounted the spare, completing the project except for the lisence plate lights which I just acquired.
There was a tad bit of cleaning weld and paint spatter required to get the axle to fit, but it finally got in there. THen I discovered a stock achorn nut would not work with evan a thin wall socket, so I simply welded two lug nuts together to form a long lug nut. You'll see why shortly
(http://i.imgur.com/18xGG9b.jpg)
(http://i.imgur.com/1Zs7QM7.jpg)

I used a little muscle to mount that tire onto the carrier:
(http://i.imgur.com/17qGOdV.jpg)
(http://i.imgur.com/wPyFBRL.jpg)
(http://i.imgur.com/6QwLjsv.jpg)

The tire wound up sticking too far aft on the initial test fit, so I marked the carrier axle and removed it
(http://i.imgur.com/4KX8Vk1.jpg)
(http://i.imgur.com/GugN5C0.jpg)

Allowing for just 1/2" clearance, the remainder of the shaft was cut off
(http://i.imgur.com/tYe11NC.jpg)
(http://i.imgur.com/Z8cq5QM.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:12:36 PM
Sliding the axle home, the fit was right on. I really liked the slight angle of the hub which allows you to rotate it to gain the most clearance.
(http://i.imgur.com/OLuAetZ.jpg)
(http://i.imgur.com/nKutCaC.jpg)
(http://i.imgur.com/iZWbPUw.jpg)

Looks like the measurement came out about where I expected it to be. This mount will carry a 37 and possibly a 38 in tire.
I haven't figured where to mount the John Deere tractor yet, which is about necessary to get that heavy sucker up onto that mount!
(http://i.imgur.com/4awGhwA.jpg)
(http://i.imgur.com/jLq2qUH.jpg)

It opens and closes with no complaint. It is all pretty rigid, which is surprising considering the weight which is cantilevered up there.
(http://i.imgur.com/FivPhIx.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:14:23 PM
Some poser shots
(http://i.imgur.com/FivPhIx.jpg)
(http://i.imgur.com/V9KAvJk.jpg)
(http://i.imgur.com/bLkWmTj.jpg)
(http://i.imgur.com/R6vubKX.jpg)
(http://i.imgur.com/5NbQI7Y.jpg)
(http://i.imgur.com/k066PaA.jpg)
(http://i.imgur.com/m7KrZWk.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:17:38 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:18:21 PM
Ordered a pair of these mini LED flood/work lights to fit in the recess either side of that new bumper. Plan to wire them to the tail-light circut.
10 watt mini light in a sturdy housing with a 120 degree beam spread.
(http://i.imgur.com/9q9ZKXJ.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:26:25 PM
Update: I plan to do the passenger side IC pipe install tomorrow. I won't be able to evaluate how well it works with snow in the forecast, but at least I should get it on.

Comment by Armalite :
Even admit it yourself. The snow has the truck shut down. Cant even make it to the mall because of the snow...

I thought for sure that this truck could handle a little of the white stuff??

....and by stlaser:
I don't know first gravel covered driveways are an issue and now this....

You know I'm starting to see a trend here. These worrisome thoughts about what his truck could handle terrain wise (or in this case not) didn't really become a major theme until he purchased Big Red. Watch out I think a set of those mattracks are going to be debuting here real soon.... Mattracks | Worldwide Rubber Track Technology Or maybe he'll start fabbing a set of his own, you know he was talking about getting a larger welder just yesterday......

Now that he owns something with tracks I think maybe he's having flashbacks of those days when he drove tanks around? Ashley, we may have discovered a new war syndrome of some sort. Watch out the lefties will be wanting to ban all of these guys from owning vehicles with tracks next. You know those tracked vehicles have been known to start themselves and drive over innocent civies at will (did I just use some of that military lingo? Note to self: gotta stop hanging around all you service members that jargon is addicting! Next thing you know I'll be abbreviating everything!).

Sorry for the rambling, couldn't sleep and this is what you all get!

....and some more ribbing by fellow "DOT" bobbyB:
Oh god no!!! He is going to make an "assault tank" ?, that has to be banned immediately .. its scary..



Flyin6's response:
I like those words
Assault
Tank
Good words to be sure

BTW, I noticed an unused 75mm anti tank gun sitting at the vfw about a mile from big red...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:30:46 PM
                                                                           (4372)
OK, enough of this silliness
On to some more modding and generally changing of perfectly good stuff!
With this next set of postings we will look at that crappy passenger IC pipe, all the aluminum stuff that connects to it and unnecessary electrical stuff.

When removing the S&B air cleaner, a quick inspection showed that the filter sock is doing it's job!
(http://i.imgur.com/gCb1sRr.jpg)
(http://i.imgur.com/Jpemt3c.jpg)

 did not remove the air cleaner box at this point, but eventually I had to, so if you're doing this project, just pull the box at this time.
After removing the large air cleaner to turbo bellows pipe, you remove the passenger IC plastic pipe. You do this by turning the clocking ring a degree or two then alligator wrestling it off. THe bottom fitting at the intercooler is the same goofy setup.
(http://i.imgur.com/aiimSYU.jpg)
(http://i.imgur.com/syv1EG1.jpg)
(http://i.imgur.com/rMFMBNx.jpg)

Next pull the connectors from the butterfly valve and disconnect the cable from the grid heater which will go bye-bye.
(http://i.imgur.com/NUQVWFx.jpg)
(http://i.imgur.com/uv3x0no.jpg)
(http://i.imgur.com/jT7bRCh.jpg)
(http://i.imgur.com/WAUpLrh.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:35:16 PM
I removed the butterfly valve, aluminum "S" tube and mount as one unit. Save the two bolts holding the butterfly valve steel bracket to the alternator housing mount, you'll be needing them in a minute.
With that done the aluminum contraption designed for the orbiter and not trucks comes cleanly out!
(http://i.imgur.com/QC1oV3C.jpg)

In these pics, you can immediately see the tube size is squeezed down significantly. Then the air has to squeeze past that very intrusive and clogging grid heater. Makes you wonder how they got this engine to make 765 torque with all this junk to contend with!
(http://i.imgur.com/6Xv4duT.jpg)
(http://i.imgur.com/cp0wqIi.jpg)

About now the parts on the floor should have hit a high water mark!
(http://i.imgur.com/qtMlNei.jpg)

The butterfly valve has a second mount which also secures the dip stick. It was all "Too big Lookin" so I pulled it and reduced it's weight some
(http://i.imgur.com/8JO2s5A.jpg)
(http://i.imgur.com/HK4UUIe.jpg)
(http://i.imgur.com/CKWGSok.jpg)

With that big hole in the top of the motor just waiting to swallow a washer or bolt, I bolted the top half of the new pipe in place with some haste
(http://i.imgur.com/IJ57woR.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:38:25 PM
Then it was time to remove the air cleaner box.
After some study, I noticed there was a cool little piece of sheet metal that came out with the removal of 3 bolts which made access to the IC easy.
(http://i.imgur.com/LOoubnj.jpg)
(http://i.imgur.com/w06xT7V.jpg)
(http://i.imgur.com/aqrkp46.jpg)
(http://i.imgur.com/frWLoMj.jpg)

With a liberal coating of silicone I slid the first coupler onto the IC nipple.
(http://i.imgur.com/2XezwGq.jpg)
(http://i.imgur.com/gjPo9MZ.jpg)

Examing the T-bolt clamps supplied with the pipes from T-rex, I'd have to recommend not to use them.
Two reasons
1. They are a siny bit on the small side necessitating way too much effort to get the nut installed,
2. The supplied clamps have coarse thread, therefore not aircraft quality.
So I'd recommend you spring for a clamp with about a 3.30" max opening with fine thread.
I use turbonetics clamps which slipped right on with no fuss at all. Further the fine thread will give you a lot more clamping force if you are the over tightening type. The nice part is that fine thread allows you to sneak up on tight without coming up against all at once.
(http://i.imgur.com/eK7buQh.jpg)
(http://i.imgur.com/eLY0kC1.jpg)
(http://i.imgur.com/W1Gryyb.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:44:00 PM
After liberally coating the upper pipe with silicone, I slid the boot all the way on and past the bead.
(http://i.imgur.com/BdNSz6C.jpg)

Here's a side by side of the stocker and Calvin's piece. THe T-Rex pipe is very obviously smoother and gets rid of that unnecessary "S" turn that has to hurt flow and generally just has less bulk and size.
(http://i.imgur.com/WZOLRqH.jpg)

When I put the pipe on the first time, I found it to be too long by maybe 1/2" so I cut the excess pipe off beyond the bead that is rolled into the pipe. After that it fit, but is touching. I plan to run it like this, then later pull off the upper pipe at some point and shorten that pipe to allow the flex coupling to do it's thing.
After some grinding and polishing, I installed the pipe and tightened the clamps.
(http://i.imgur.com/3doz1C1.jpg)

I noticed the air box was pulling some debris in throudh the lower hole which I had plugged earlier. SO this time I sealed it with RTV semi permanently.
(http://i.imgur.com/BKfM06c.jpg)
(http://i.imgur.com/yi2crg3.jpg)

Then the air box and air pipe was reinstalled which. Prior to that I retaped the electrical power cables back up and secured the several unused plugs.
(http://i.imgur.com/jZ2ljZH.jpg)
(http://i.imgur.com/vIC2ySG.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:45:42 PM
I then went into the wheel well to button all that up, and that's when I discovered it!
The truck was destroyed!
And I didn't even know it!!!!
Just look at the horrible damage:
(http://i.imgur.com/0qiRteb.jpg)
(http://i.imgur.com/W8eBRtb.jpg)

Yes, I know, it's awful
It's mud of course and I had no idea the truck was in such bad condition.
Then I checked out the engine and found this:
(http://i.imgur.com/gtPuhsm.jpg)

Yes apparently the engine is destroyed also!
I managed to find a bumper bolt from the one I just pulled off and plugged that hole in the exhaust manifold...Maybe the truck will manage to limp around now, who knows...

Anyway, I buttoned it all up and started it up. I can testify that the engine definitely revs quicker and wants to get to higher RPMs more quicklier.
Any of you who have ever been to the SERE course at Bragg know that word, nuff said...
SO, we have church tonight so I'll see how it runs and report back.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 17, 2014, 10:51:05 PM
                                                                                                             (4393)
I can report that that pipe made a difference.
The EGT's were lower, as in I didn't see anything over the 900's. The caveat is, however that it was snowing lightly and I didn't get in to it all that much. The motor revs quicker and is smoother.
Pulling onto the highway from the onramp the traction light kept coming on with the wet road, when it never did that before. I'd have to say the motor is making more torque than before and it comes on very smoothly. That pipe was definately worth the money!
Hats off to Calvin and his T-Rex "make everything happen" diesel performance shop!

Quote:
Originally Posted by c************
"what were your egts before the ic pipe? i noticed a difference in throttle response in mine also but if its cold outside and your trucks not plugged in it has a hard time starting.. when mine fired up after sitting overnight it stuttered for 5 seconds like it was missing then continued its normal cold start.. i hooked the heater and the butterfly valve back up today and am leaving my truck unplugged tonight to see if it makes it healthy again. even with the stuff in place it made a good diff. calvin is the man. and good write up don"

When I started it in the cold garage, it fired up normally.
It was parked in the lot outside the church for about 2.5 hours last night. It had ice on it. I started it and it fired right up and ran normally, well, actually, it ran more smoothly then when it had that clunky valve.
I still believe the heater is for EGR purposes only and not for cold starting, can someone prove me wrong on this please?
EGT's:
When it was with EGR, I'd see 1300's. With EGR removal, then only 1200's. When I added Ricks manifolds and up pipes, honestly, it seldom gets into the 1100's, mostly stays in the 900-1050 range. Last night while hammering it the little bit I could, I was seeing 700-mid 800's. Maybe I saw a 900 for a flash, don't recall...
If I add the water meth, I can then probably begin using it as a refrigerator!

Quote:
Originally Posted by FC****
"Well at least I wasn't kidding myself when I noticed more response the the power bands. Watch your max boost when you get a chance. With the larger tube I noticed a 4 psi loss. But I did notice and videoed it my egt has dropped on wot runs. Ill make that psi drop up here in a few months. "



Keep in mind PSI is not important, however the volume of air getting to the combustion chamber.
Think about paint guns. The standard high pressure paint gun uses 40-50 psi to forcefully push out that paint. However about 40% of the paint actually bounces off the surface and ends up becoming airborne dust. The newer HVLP (high volume, low pressure, uses half or less the air pressure to spray the same amount of paint. And know what? Because the paint isn't hurling out at mach 3, more of it sticks to the surface. Less pressure, more material moved.

I used to run a buick grand national. Hence the "flyin6" at least part of why that name came about. I mean, sure I was flying for a reason, but the buick would just about fly. The buick had six cylinders, but in the Army the guy in command was often called "six." OK, back to the buicks, built stockers were running 25 psi to get the job done. But guys in the know would concentrate on getting more volume as a much lower pressure to actually make more power. Hey if a caged, framed car weighing 3800 lbs could run in the 10's and still be driven on vacation, there must be something good going on with the concept...

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 18, 2014, 10:24:52 PM
Quote:
Originally Posted by R****
"Looks good...the snorkel seemed to be the only thing missing from an otherwise very capable off-road survival vehicle." 


Snorkel would help, but not for the reason you mentioned.
Right now that truck could probably take somewhere from 30"-40" of water with the top of the engine and electrics above the planning water. That would keep the intake dry, still
Getting into water any deeper, and you will lose traction due to flotation, so practically speaking, I think I can do truck right up to the point where I do boat and plug along just fine.
The reason I could use, and brother Ashley absolutely needs a snorkel, is dust and dirt!
I learned this lesson over in the sand pit shooting gallery. The wheels obviously churn up the dust and vorticies circulate it in and around the wheel well. As we know the air intake sits just above all that on the other side of the wheel liner. Eliminates some, but not nearly enough of the dirt, so the air filter becomes the last line of defense.
OK, so if you only positioned the intake a few feet higher, you would have a nearly dust free area from which to draw air. SO that's filter effect #1.
Top the pipe off with a device that causes a strong vortex (swirling) action that ejects particles which have been centrifuged to the outside of the cylindrical device and you have filter effect #2.
Then place the actual intake pipe in the center of all that and you have filter effect #3.
Finally the air is routed to and through the natural filter and bingo, filter #4 and berry, berry kleen air is available for all those compressions to chew on.
So that would be the reason, my learned padawan, for stickin' a kintucky stove pipe up the side and to de top!

Here's a pic of the snorkel I built for my Tundra. That was made from a long section of 3" steel tubing that was cut and sectioned about a hundred times and then filled in with body filler to make it "rounder."
(http://i.imgur.com/cBy8loV.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 18, 2014, 10:30:52 PM
I'm in the middle of relocating the PCV vent from the turbo when this shows up at the door:
(http://i.imgur.com/tUjXAKi.jpg)

Well, after making a straight run at it, I completed the PCV delete.
I vented it to filtered atmosphere to remove any oil residue that could possibly foul the turbo inlet and to get rid of the restriction on the inlet scroll.

I purchased a readily available catch can with vent available from summit designed just for this purpose.
(http://i.imgur.com/P7paUYr.jpg)
(http://i.imgur.com/0laMi42.jpg)
(http://i.imgur.com/jtP15PT.jpg)
(http://i.imgur.com/U52ZbhR.jpg)
(http://i.imgur.com/yEZzprx.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 18, 2014, 10:33:11 PM
First think I did was paint the parts and cook up some crab cakes. Both turned out fine.
(http://i.imgur.com/aIBjyXN.jpg)
(http://i.imgur.com/RkeSKSe.jpg)

In the middle of painting parts, cooking the cakes, then painting some more, and trying to eat, the neighbor called telling me my dog was digging up her yard. Well you already saw the disaster there. That mutt is still locked in the woman's garage awaiting a fire hose to clean that mud off.

Then I drilled and tapped the can flange for 5/16" X 18
(http://i.imgur.com/F1ovSus.jpg)
(http://i.imgur.com/ydz26LS.jpg)

The air intake hose came off next followed by the PCV inlet diffuser valve. Note the "thing" sticking into the air tract creating vortices...naughty...naughty!
(http://i.imgur.com/hEKRDxV.jpg)
(http://i.imgur.com/ssv49Ts.jpg)
(http://i.imgur.com/tXEguqX.jpg)
(http://i.imgur.com/CLGrgYe.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 18, 2014, 10:36:13 PM
                                                                               (4560)
Hmmm, fuzzy pic...oh well everyone just deal with it, get over the traumatic experience and let's drive on

OK, next the inlet scroll comes out .
(http://i.imgur.com/dFCsiwI.jpg)
(http://i.imgur.com/uVjYDhG.jpg)
(http://i.imgur.com/nH4AqWN.jpg)


 
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 19, 2014, 09:18:37 PM
Hmmm, another fuzzy pic, starting to stress here, but I'll be fine, I think. Sort of like that hopeless feeling when you get all mired in a mulch bed over at the mall with only kolean kars parked around and their zoned out 16 yr old drivers...Yea bad deal

OK pressing on, Here's some lookie-see shots of that gaudy thing messin with the air molecules in the inlet:
(http://i.imgur.com/Lc6KlLE.jpg)
(http://i.imgur.com/S3V8k5C.jpg)

So, I ground all that plastic out of the way, but have no fear I didn't get it all over, just in my eyes.
(http://i.imgur.com/qaLj49m.jpg)
(http://i.imgur.com/4qNKupc.jpg)
(http://i.imgur.com/EUQUsg9.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 19, 2014, 09:20:19 PM
With the restriction gone I started to have flashbacks from one of the wars I attended, don't remember which one, it's not important, but with that killer face on, I grabbed the hacksaw and took out my frustrations on the PCV valve
(http://i.imgur.com/I9n3O0W.jpg)
(http://i.imgur.com/68H5CkM.jpg)
(http://i.imgur.com/738rpJD.jpg)
(http://i.imgur.com/no891sF.jpg)

 didn't like that big hole so much, so I drilled a whole bunch of little holes to keep it company around the inside circumference, then mixed up a batch of resin, taped off one end and poured it full.
(http://i.imgur.com/yVBsglO.jpg)
(http://i.imgur.com/rGLcBYd.jpg)
(http://i.imgur.com/okCHHhv.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 19, 2014, 09:22:45 PM
While waiting for that to cure, I went to rippin' and tearin' again
Here's that nasty factory PCV hose

And after attaching the new hose, I laid it on the fender and was done!
Engine is now vented to the atmosphere!
(http://i.imgur.com/R3FUyIK.jpg)
(http://i.imgur.com/EiKT0ry.jpg)
(http://i.imgur.com/qFBmNL1.jpg)
(http://i.imgur.com/eRzs1Ts.jpg)
(http://i.imgur.com/yeIfS6X.jpg)

That's when I stared out the window, the one that is now useable again since all the parts boxes were used up. I immediately noticed a mud-dauber nest!

Darn, that's right, they build those nests in everything with a hole in it. The way my boys sleep, I wonder if they ever had to pick any out of their, well, never mind.
So with mud daubers in mind, I decided to create something a little fancier for the end of the hose.

There isn't much room under the hood with 400 cubic inches and 8 miles of wires, so I spied an appropriate spot and went to work:
(http://i.imgur.com/DLENMDq.jpg)
(http://i.imgur.com/m5U2HTc.jpg)
(http://i.imgur.com/1W3gy1C.jpg)
(http://i.imgur.com/HIRCHUw.jpg)
(http://i.imgur.com/lsZLT70.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:40:36 PM
That brace is just too big and taking up space I needed, so we compromised and like a contestant on biggest loser, it lost some bulk
(http://i.imgur.com/bVmtHMv.jpg)
(http://i.imgur.com/9sASvpV.jpg)
(http://i.imgur.com/ZIzIeXc.jpg)
(http://i.imgur.com/CPVb1yg.jpg)
(http://i.imgur.com/MMB0ut2.jpg)

With that piece in place, a short arm to attach to the can was cut out of 11 gage sheet steel.
(http://i.imgur.com/RmufhW0.jpg)
(http://i.imgur.com/crRQxUp.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:43:18 PM
Next the can assembly, well, became an assembly, after, well, assembly!
(http://i.imgur.com/OvaIdgc.jpg)
(http://i.imgur.com/kxZ0iPf.jpg)
(http://i.imgur.com/gLBG6lW.jpg)
(http://i.imgur.com/elPBgWj.jpg)

Purdy little top had, don't ya think?
Next I did something else:
(http://i.imgur.com/uhtfDmj.jpg)
(http://i.imgur.com/GLahxqQ.jpg)
(http://i.imgur.com/JtBaFFI.jpg)
(http://i.imgur.com/KYJStmL.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:45:48 PM
Next I applied concentrated sparks to it in several different ways

Then some paint to hide the damage
(http://i.imgur.com/nXp8TuM.jpg)
(http://i.imgur.com/8GvVWc9.jpg)
(http://i.imgur.com/7nJZDGC.jpg)
(http://i.imgur.com/6zwpLoz.jpg)

While waiting for the John Deere paint to dry, the intake scroll whtch-ah-ma-kall-it slid back together minus all the vorticie makin' protrusions.
(http://i.imgur.com/qOy70qE.jpg)
(http://i.imgur.com/R66vuSG.jpg)
(http://i.imgur.com/yc3hpZK.jpg)
(http://i.imgur.com/k4Zg4Rc.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:47:22 PM
That piece was reinstalled along with the intake hose/pipe thing.
(http://i.imgur.com/v07viQD.jpg)
(http://i.imgur.com/Op6UPVP.jpg)

With the paint dry enough to smack it around like my neighbors when they bother me, the whole thing was bolted inplace and the vent line connected. And, yes the hood closes!

So that's one way to delete your PCV, now that we know it's easy, get on it!
(http://i.imgur.com/d5ZNJ0i.jpg)
(http://i.imgur.com/eoqS2nP.jpg)
(http://i.imgur.com/eLbBDRo.jpg)
(http://i.imgur.com/srFxbrR.jpg)
(http://i.imgur.com/NGuVRHM.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:50:16 PM
Update on the PCV delete mod.
I want to say the truck feels more torquey than before. It just seems to have very good throttle response, and I'm wondering if that is psychological or real. Nailing it it still gets all jiggy and the max EGT I was able to generate on a longer pull was 1153 and only for a second.
It would seem everything you do to this engine to make it breath better results in lower EGT's as well as more oomph.
None of this is verified, of course. But there is no denying the truck does indeed run well.

So, here's what is in store for the truck this coming week. I already ordered some air bag helper springs. I plan to make some custom mounts and get them installed.

I am changing up the shop getting ready for the tactical topper project re-energizing. Today I purchased Harbor freight huge tool boxes and transfered the tools from my hopelessly over packed 40 year old boxes. I will clean them up tomorrow then make hardware storage out of them.

I am pulling the Tundra down into it's component parts, then I will haul the big pieces out and be done with it. If anyone needs a project truck, here's you opportunity to get one cheap. Once that is out of there, I want to do a couple day redesign on that side of the garage, then get the tac-topper torn down ready to go into phase next.

In the middle of all that, I think I'll mount the spare and water cans onto the combat gator. No sooner than the pole barn is built down on terra-farm, the Gator will get relocated as well...

I have one other super cool truck project looking at the moment, but I will withhold the particulars until I figure out if it all will fit... I guarantee you'll will love it!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:52:33 PM
Today, I balanced and rotated the tires.
This time, however, we removed the pressure sensors and installed a bag of that poly balancing powder in each tire. Doing so necissitated removal of the pressure sensors.

Normally, removal of those sensors would each trigger a low pressure light and illuminate the tire pressure low caution symbol.

However, I built a little $10 device to trick the system and make me happy.

Here's the pieces parts:
(http://i.imgur.com/3PLL6WN.jpg)

All I did was to create a portable little pressure vessel constructed of schedule 40 PVC rated at over 300psi, using a tire valve stem, and sealing the sensors inside. Once glued shut and allowed to set up, I pressurized the tank, and strapped it under my seat!

Done

Perfect balance on the tires and no flashing messages!
(http://i.imgur.com/dmO1t8h.jpg)
(http://i.imgur.com/aO7axsL.jpg)
(http://i.imgur.com/FB0lYrf.jpg)
(http://i.imgur.com/kNfleGL.jpg)

And the finish:
(http://i.imgur.com/Vc5eukO.jpg)
(http://i.imgur.com/6VGbnlV.jpg)
(http://i.imgur.com/vVANCVs.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:55:02 PM
Here's something else of a mild concern

Take a look at this photo and what are you looking at???
(http://i.imgur.com/4wpsds3.jpg)

Are you noticing the dark then light, then dark variations of that loss of traction event?

What causes that is the torque of the drivetrain and powerplant winding up the rear spring into an "S" shape, then the spring violently recoiling. ANd over and over. When the spring wraps up, it pulls the tire upward resulting in a loss of traction and tire patch contact.

We call this wheel hop, and this is what it looks like.

So

Looks like traction bars are in my future.

A custom set of course!


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:55:12 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:56:40 PM
Just got off the phone with Ryan over at Industrial Injection.

He posted in another spot about their soon to be compound turbo kit.

He says it is one of their best engineered kits to date and is looking at a release in a few weeks to market.

I believe I will sign up to bolt one on and see how well it works. I suspect it will do a great job of forcing more air into the stock turbo which should lower EGT's substantially and create the foundation for a lot more horsepower.

Obviously with the arrival of injectors, a gooder high pressure pump (Mo-fuel), and tuning to make it all go bang at the proper time, this kit could produce a mountain of useable power. So that's the big caveat, it will be a great addition in a foundational way for future growth.

More to come as I get information and pictures.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 10:59:34 PM
The focus will be switching to suspension for the next little bit

With that axle wrap and me looking at those blocks, well, me isn't that happy with all that, so here goes again!

The short plan is to add in the air bags, although on more or less, custom mounts.

I have also started the process with Alcan Springs to build out a set of techy custom springs to get rid of all the blocks which will help control body roll a bunch. Those will all get done over the next month. After adding them in, I will decide if I need a rear sway bar or not.

Meanwhile, I have a radical front sway bar setup coming together that is something never seen before on a HD truck. It's definately different and that gem will be going onto the front end.

After that the front droop bump stops are going to go bye-bye and a set of air-bumps installed to control the added droop out and probably a set of longer travel shocks.

We'll see how the rear shcoks go. Since I relocated the lower shock mounts, I got a lot more droop-out back there, but with the new Alcans, there will more of that going on.

Initially, I'll have to build a ramp to test the results of the mods to document the changes.

Oh, and I may have a cure for the common turning radius problem which I seem to have (All lifted trucks have, actually)

And of course, the tactical topper will shortly be reclaiming it's spot in the shop...

......Well, I've been busy sourcing the next batch of parts. We will be diving into the front and rear suspension as well as doing some exotic things to the engine.
This morning I'm off to get the truck weighed, front/rear/total so that some really smart guys can design me up a set of springs to make my truck mo-better!

Something else has caught my attention and will deserve some attention. Along the multi-fuel theme of this pseudo-survival vehicle I think I need to start looking into exactly that. I have done some homework already on bio fuels (Chicken grease) and the like. There are some technical difficulties with regard to fuel mapping since the fule immersed injectors operate in the manner they do, given the viscosity of the juice they're squirting. Change all that and the ratios could go bye-bye. Soy based bio fuel is mo-slippier than the EPA crap forced upon us, ULSD.
But fear not, that code can be broken and we can figure out how to harden the fuel system to run that fuel. We already know Jet-A is dryer and harder on diesel pumps, OK. Waste Vehicle Oil is all over the spectrum and Waste vegetable oil, requires a bit of a process, however for around $1500 one can make around 50 gallons a day.

What we haven't looked at and I believe is the next big thing is LNG!
The US of this A is covered with it. Liquified natural gas is so cheap to produce that folks will stop making the stuff for lack of a decent profit margin unless demand is increased exponentially.
Read the book of Don, chapter, "Stuff that makes sense" and you'll see that all the money guys (driven by the desire to make more) need to do is to create a market.
So what, build ten million new homes? Naw, don't think so. Convert our nations heavy trucks to LNG, hmmm, for a dumb pilut I just might be on to something.
Gentlemen mark my words, LNG is coming to a neighborhood near you and it should be in the sub $2 a gallon range and will decrease over a few years before stabilizing for a long time around $2 a gallon. So, I think I need to cipher all that out and get some piliminary plans cooked up!

OK, off to the weigh station, wish me luck...plenty of jap and kolean kars along the way, and rusty fords!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 11:00:09 PM
Just got back from Looking at Big Red

and Weighing the truck

Both were surprising to me.

Big red was making all the other Case heavy equipment look, well, uglier, yea it's that bad looking!

And that truck of mine is heavy

Here's the official results

Front Axle: 5040 lbs

Rear axle 3560 lbs

Total weight 8600 lbs

I was in it and it had a full tank of fuel and one fuel can full as well
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on November 24, 2014, 11:01:01 PM
                                                                                                                  (4665)
Zooming out to the big picture here, Tentatively, I was contemplating adding both air bags directly on top of the differential housing.

Allow me to 'splain Y...

The suspension is about to undergo a metamorphesis (Yes I know I kan't spel) Jus cus I writ ah buk dosnt meen I's kan spel korrectly!

All right moving on...

I plan to build a lot more flex into the suspension starting pretty soon. With respect to those air bags, they get bolted to the axle and the frame, as in they aren't moving at those points. I think there comes a point where one side of the axle droops out enough to literally tear those bags apart.

If, however I mount then at the roll center, then they will move very little with respect to drooping out one side of the suspension.

I will have to construct another cross member and fab up a base, but that's about it.

THe first thing being built is the rear springs. After talking with Fernando at Atlas Springs last night, I decided they would be building the rear springs. These springs will be designed to carry around 3600 pounds and probably have a dual rate. He was talking about some of the spring being 120 lbs/in and some of it 140 lbs/in. He is into the durometer of the rubber of the bushings and all sorts of technical stuff. The springs will be built with 4" more arch to eliminate the Fabtech lift block and therefore reduce the rolling I get going around corners somewhat.

So it looks like maybe air bag, then springs, and possibly something else...

A shackle flip. Cool part about that is by lengthening the actual shackle strap and angling it forward, all of that can be made into a bunch more droop out.

I think I will be shooting for a 70/30 or 65/35 ratio of suspension travel between the rear and the front. That works pretty well for IFS with some mo-off road capability.

Remember, the thing I really want is to leave the road at a high rate of speed to enter a field and not sustain damage. Whilst (Queens english) the Hyundai with the biker gang in tow folds up and serves as moving target practice when I stop for a moment...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:15:01 PM
Posted by stlaser:
Couple of thoughts and I'm throwing these out at random so bear with me here...

First, why are you sticking to leaves? They limit you in so many ways that I don't even know where to start the list at? Your not hauling big red around and in essence this whole idea of using a truck as a truck flew out the window a long time ago.

Why not attack this from a better angle, ditch the leaves. Then double triangulate a four link, finish it out with coil overs and something special.

I haven't viewed your design for the bags in the middle of the axle but I'm lost in that regards as well as to why?

And I'm not going to let the cat out of the bag about the stuff that was discussed yesterday but here again the leaves limit you so why go to all the trouble for a lack luster result.

Obviously I hate leaves, they suck in a off road environment and every bracket gets hung up on something when your traversing the terrain. In essence you want one of our KOH rigs that can go mountain crawling or 150mph across the desert floor. Leaves ain't gonna get the job done. Not to mention your spending a mountain of cash to keep adding band aids just for the sake of keeping those dumb leaves.

The front IFS is fine, you know this. In fact the high dollar KOH cars like the one Campbell runs has IFS and a trick LS7 or 8 or whatever the last revision GM put out and his IFS fronts hold up. So set the rear up like it should be and haul those stock leaves to the junk yard where they belong already!
Sorry, that was a mouth full but this has been bugging me for a couple of days now......


You know, if you look in the middle, not to full flex trail busting but in the middle between that and stock, there is an area. That area fits well into the cost effective arena where one is spending $700-$1000 in lieu of the money to link stuff up. Last time I linked a truck the coilovers cost me $1200, jonny joints, tubing brackets and the like, a ton more.

So, that's my short answer why a flexy leaf spring pack is a pretty good solution considering it will be much more advanced that stock, and that stock does a pretty good job in-in of its own.

We may not agree, but that's why I'm going with Mr. Leaf (ies)


stlaser:
Sorry, I look at the rest of the truck (over the top) and then I see you sticking with leaves (which did I mention I dislike?).......

Ya know, I think you did mention that...

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:17:19 PM
Quote:
Originally Posted by KensAuto
That's a shame....to miss out on all the great conversations, like one guy trying to convince another guy, that was born in the front seat of a leafsprung model A, that someone actually makes something a little more advanced.....like coils of spring steel (w/less mass and 'bind') instead of a bunch of flat pieces bolted together in some primitive matter. haha. Actually goin' to take Don's side on this one, just cause I ...........................well, not sure why. Maybe I'm in a good mood today.


stlaser:
I'm confused, was there something positive backing up the old guy's stance? I must have missed that part.....
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:22:58 PM
Posted by Armalite:
I have to play opposite Don here... I like the idea of the coils. Allow more flex, and a good ride. If you wanted to go way out there with the duramax, then come up with a rear coil suspension, and let the leafs by by-gones ! I completely get the leafs for what the truck was designed to do, but, you have cleared that hurdle about 23 pages back...

Both function and serve a purpose. Just me personally, I would like to see a coil rear setup for an off road duramax.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:23:47 PM
Posted by stlaser:
My opinion is if he tries to go from good road to dirt those leaves are going to hate life and your back is going to hate it as well.

With that said I understand Don not wanting that 4 link crap and the fact he encountered problems on his tundy up front with it. However that was a steer axle and things can get slightly more complicated in that regards.

I like the thought of bags and coils, plus the fact that if he builds the lower links correctly it will have a positive impact on the amount of jap cars he can run over as he will slide on those bottom links and the other added benny is protecting that rear driveshaft as a result. IMO too many positive to stick with crappy leaves. Did I mention I dislike leaves?????
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:26:12 PM
Flyin6's response:
I have a story I haven't shared yet, a horrible tale. Has caused me many a sleepless nights.
Once upon a time in a land far, far away I was driving a truck, may it rest in peace, that had those coiled snake springs out back just waiting to unleash their pent up energy upon some poor unsuspecting someone.
Well, sadly, the day came.
It was over at the mall, on the Ohio side. State regulations (I later discovered) allow those massive walls of granite to be 1/4" taller than the mountainous ones we have here at the kintucky. Well, my vehicle, the mighty hummer was humming right along when I saw it. It was upon me before I could do anything! Even with my finely tuned and trained sense for impending danger and my lightening fast reaction I was unable to do nothing and the might H2 plowed directly into the front precipice of that towering wall! The violent compression of the front suspension caused the statue of the hula dancer on the dash to wiggle, and outside of normal limits. I'm not going there but it was practically obscene!
Then it happened...The rear of the vehicle, which was still connected to the front at that time struck the monolith! The forces the impact generated rivaled those present at the creation of the universe! During the violent crash sequence, somehow the coil spring became slightly dislodged on it's mount...I believed it actually turned a quarter of a turn, rendering the vehicle undriveable. I actually had to have it towed away and since it was all horribly twisted as evidenced by several areas of streaking in the dust, I could not even trade the vehicle and had to have it crushed. I found out later they made one hundred fifty elantras out of the scrap.
So it may be all funny to you two clowns, but to me, talk of these awful coils dredges up old hurtful memories which I thought I had put to rest.
I hope you two feel good about yourselves!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:26:26 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:30:30 PM
Getting parts and steel together for the air spring install. Looks like I will be making a custom crossmember if I do the center mount concept
I was thinking about how that might affect rolling in the corners. I have to do more research, but just putting the bags outboard should work against body roll whereas placing them in the center might aggravate the roll issue.

I definately need to think this one out

Any suspension engineers out there with something to add to this conversation?
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:34:06 PM
Quote:
Originally Posted by *****
I have never seen bags in the center. Ever. Corners. Viair for the control valves. The best possible is Viair.

I have, although I cannot verify if the system worked properly, I am beginning to suspect it is not an optimal setup
I found some roll center force calculations and sure enough if you move the roll center higher and the pivot point inboard, the roll forces can be compounded.
I'll have to rethink the design I was contemplating...

I'll explain what I was going to do.
I am having Atlas Spring build me a new set of leaves that will carry the weight I anticipate once the tac topper is installed. I planned for the springs to carry the empty weight which will be 3800ish, then add in the bags to carry the weight beyond that, say when I add fuel and water to the cans and fill the back end up with stuff.
Knowing I was going to add a rear small diameter sway bar to control the roll when off road and going slow, I thought I'd get the air springs high up in the center where they are away from everything,
Then I started thinking...
Then the post and conversation
Then I found the engineering formulas
Then I plugged in some numbers and found
THat Zeakes comments were correct
So, we'll switch back to air springs to the outside, and just work out the mount issue.

And I get the whole leaf spring twisty thing. I played at that game a lot with the tundra which still sports a set of custom Alcans out back. I discovered all sorts of ways to get more twist out of them and that is what we are currently doing with the Atlas spring build (I think)
As far as the contraption bar, I have discussed it with the Atlas builder so we'll see if he can design the hop out of the spring. If not, I'll add just one exactly like the one I designed and welded up to my tundra...I'll see if I can find some pics of that build



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:35:51 PM
Here's that contraption bar
What you can't see is the front
It is attached to a shackle which freely allows up and down movement, but when the axle tries to twist, that bar is pushing or pulling straight up and down
(http://i.imgur.com/0C3fbXN.jpg)
(http://i.imgur.com/JL2OGtR.jpg)

...and yes, I cut up one of the 3-point tractor linkages I had laying around to build part of it!
Note to self: Do not ever use tractor heims for automotive builds!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:39:33 PM
Oh, I installed a 5watt solar panel on both Big Red and my attack Gator today. Then I went a little crazy and painted, well camoflaged the Gator. You can see it over on it's thread.
Here's the 5 watt panel which is going to be installed in the D-Max as well and a sneak of the gator paint:
(http://i.imgur.com/69umq10.jpg)
(http://i.imgur.com/xZZHnML.jpg)
(http://i.imgur.com/XydJmIF.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:42:33 PM
While I'm sorting out bigger projects, I added a solar panel to the D-Max today. I found a 5watt unit for around $40 complete with a battery charging circut.

I modified the unit by adding the charge regulator directly to the panel, then taking an old unused power outlet plug and wiring that onto the circut board.
I fashioned some feet for the panel which I will add some velcro to.

The plan is to mount a couple of strips of the "hook" side of the velcro to the panel housing the passenger air bag and just set it in place. That will allow me to use that real estate while maintaining full function of the air bag.

Here's how that all went:
(http://i.imgur.com/4tZ92tw.jpg)
(http://i.imgur.com/dgs26cx.jpg)
(http://i.imgur.com/0aMfOTC.jpg)

The "feet"
.032 aircraft aluminum
(http://i.imgur.com/OxZDwZm.jpg)
(http://i.imgur.com/pYzKQPv.jpg)

"Feet" installed and some John Deere black paint and gun lube covering the position revealing shiney aluminum, making it all nice and tactical!
(http://i.imgur.com/0Extqea.jpg)
(http://i.imgur.com/luRs0OG.jpg)
(http://i.imgur.com/gJle77R.jpg)

Here's where I plan to stick it:
(http://i.imgur.com/qJ4iNg5.jpg)
(http://i.imgur.com/hb8RpX1.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:48:40 PM
Here's some painting going on, tidying up the rear bumper some:
(http://i.imgur.com/GZBNk2c.jpg)
(http://i.imgur.com/tcbjfSq.jpg)
(http://i.imgur.com/Dij3sDq.jpg)

Next, I cut down the axle and the face of the mount as well to allow me to slide the tire in closer to the tailgate. I gained about 1.5" and looking at it, I have maybe 1/4" more space to get if I cut some more.
(http://i.imgur.com/PndUa6L.jpg)
(http://i.imgur.com/9RQQ4vy.jpg)

And now that the Tundra has gone on to greener pastures, I am reworking that side of the shop to make that space more efficient. I am using that concept, where everything has a space and spot and it will remain there until used. I even busted out some drywall under the stairs to get room to slide in two or three floor jacks.
(http://i.imgur.com/iDCKitk.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 02, 2014, 10:49:55 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:18:14 PM
Let's get some more stuff done on Mr. D-Max.
I saw a neat Mag light with a LED in lieu of a bulb and some neat flashlight holders. so's I's does the math and thar she blows, freshlee mounted all pretty like, and where my old joints can still flex to grab it!

Here's how that worked out:
(http://i.imgur.com/bvmIpgp.jpg)
(http://i.imgur.com/4EVH3qV.jpg)
(http://i.imgur.com/0GduxsR.jpg)
(http://i.imgur.com/GKMfnWJ.jpg)

A couple more shots
(http://i.imgur.com/NWL3Ocm.jpg)
(http://i.imgur.com/dHzkfNf.jpg)
(http://i.imgur.com/UvRRoaL.jpg)
(http://i.imgur.com/c396gtJ.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:21:24 PM
I've been busy on doing a makeover on the shop area as well...With the tac-topper project coming right up, I need max space to fabricate and a lot of organization.
I started all this by buying those new tool boxes. Well, then when I started transfereing those old tools into that new box, well, the box actually rejected some of them!
Really, it's true!
I'd put the old nasty scuffed things in there then the next morning they'd be scattered all ofer the floor...just sayin...
I can't explain it either, and frankly, the wife isn't buying it, but that's my story and I'm stickin with it!
So I spent a small fortune restocking it with new shiney stuff, and know what??? Yup, not a tool sent flyin' yet!...Fixed that problem.
(http://i.imgur.com/JDgkEbm.jpg)
(http://i.imgur.com/SfnFIPE.jpg)
(http://i.imgur.com/MYjyL0q.jpg)
(http://i.imgur.com/WljarGG.jpg)
(http://i.imgur.com/XOMXN9q.jpg)

Next up, I restocked the hardware, spending the rest of the small fortune I used to have, making the cost of the make-over so far, a medium fortune!

I cleaned and retasked the old tool box into a hardware bin and made that all pretty as well. For you DOT's out there liiokin for the finest thread from which to spin some fantastic lie, i must have done all that in between naps!
(http://i.imgur.com/YAs29tW.jpg)
(http://i.imgur.com/9M6kgfm.jpg)

On the opposite side of the bay, where the Tundra had grown roots, I have been busy as well. First I knocked out the drywall under the steps creating room for two floor jacks and some jack stands. I had to rebuild the spindly guard rails as the little arangers have been doing what Rangers do, break things!
Next I removed the 36" table in the corner and remade it into a 24" table with a shelf. THat now holds the steel and tidys that corner up nicely.

This Thursday, the Chebby bumper and that big box gets handed off to a trucker bound for Calif, and it's new owner and by then I'll have the rest of the area policed up and ready for another mess!
(http://i.imgur.com/wzcA2QT.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:22:44 PM
                                                                                                                (4898)
Picked up some cool survival thing-a-ma-bobs
I found the smaller knife for $4 and the larger one for less than $20. Not the best quality, but good enough to hack away on things then throw at Kolean Kars.
I became fascinated at the LED light thing and picked up an assortment of replacement bulb things which will find themselves in my older mag lights in the not too distant future.

Also picked up the Army FM's (Field Manuals) and survival handbooks. THere's some pretty cool things in there, and lots of pics so we pilots will be able to understand!
(http://i.imgur.com/NvjqKJi.jpg)
(http://i.imgur.com/BHz96hW.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:25:19 PM
Project Big Red is getting a set of sweeps at the moment. They are 3" X 4" X .250" rectangle steel roll bar extenders. They will extend forward from the roof out to the front of the hood. That hood is made out of 1/2" steel! So it's super Duper strong. THe concept is to keep a falling white oak or jap car from wiping out the air cleaner and exhaust stack and possibly entering the cab area where it would quickly dispatch ole Big Don. Yup, falling trees have lots of stored energy, and they are usually pissed that you just knocked them down. SO just to keep everything on the up and up, I'm spending more of the national budget keeping that ugly red/orange/grease paint from getting scratched up!

Oh and It is that time of year once again. The landscape people dumped a load of mulch on the driveway. I shuttled most of it away with Mr. J. Deere, but enough remains to make the parking area a very dangerous place. Earlier today I got a wheel off the safety of the concrete and into the mulch. In a flash I was buried up to the frame in a 8" pile of the stuff. The grizzly was 'ah grindin', the tires were ah' squealing, and the Allison was eating over a grand worth of torques and yet with all that...nothing! I was buried for probably years. But then I remembered I had a sled dog! So I ran my winch line out to her and tied her up and gave her a hearty "Mush"
And just like that I was free!
Later I'm going to install a mount on the side of the bed for that dog, just in case I get near any more mulch!
(http://i.imgur.com/7rAtjIH.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:29:35 PM
Lets get busy melting steel and cutting stuff up again!

THis time we will be installing the rear air bags, well sorta

Didn't quite get done

Anyway, Here's the box and the stuff. I am going to use somewhere around 1/2 to 2/3rds of all that stuff.
(http://i.imgur.com/nq5jdpT.jpg)
(http://i.imgur.com/bUYlZAo.jpg)

Some of the parts are great and others are awful! The lower spring mount uses long bolts which extend about sixty feet below the axle, and seem to be designed to catch anything you might have missed by carefully maneuvering off road. So those along with the entire lower mount will become the parts of scrap heaps and one day a Kia I am sure!

Here's what it all looks like before I went crazy, or before I started chopping stuff up, I'm already crazy, well actually, I can't remember if I'm crazy or not, I'll get back with everyone on that one later!
(http://i.imgur.com/v8JvGqZ.jpg)
(http://i.imgur.com/lyvjMB0.jpg)

The upper jounce bumpers are all in the way, so they go bye-bye.
That intrusive lower block with it's mega bumper pad is also in the way. That too will take a hike after getting blasted by some high velocity gases.
(http://i.imgur.com/UIcUyat.jpg)

Then I started sawing stuff out of the way:
(http://i.imgur.com/KoEgbYz.jpg)
(http://i.imgur.com/ytdFD9U.jpg)
(http://i.imgur.com/snPhDYh.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:31:21 PM
After cutting away the jounce bumper mounting cup, I wasn't happy, so those feelings of incompleteness would lead to more sawing, blown circut breakers and over-heated tools!

After experimenting with the air bag placement I decided to flip the bottom plate to keep it away from Shawn's U-bolt flop plate and all it's massiveness.

Not done with that gem either me thinks...
(http://i.imgur.com/I24QOoH.jpg)
(http://i.imgur.com/jPOq5rD.jpg)
(http://i.imgur.com/muBH6uK.jpg)

This was the point where the itch got to me. I kept thinking about that gaudy mount part just ah'hangin there so I decided to overheat my saw again. After just one of those pieces, it was smoking as much as the steel I was sawing through!
(http://i.imgur.com/92EcTED.jpg)

The pile of parts being removed is growing larger...
(http://i.imgur.com/67VZjcf.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:33:44 PM
You might have noticed the air bag is rather short, that's because it is!
It was designed for on road vehicles that require additional control when hooking heavy loads.
To make all that work on a pseudo off road truck, something is going to have to move a bit more than those engineers had considered.
The air bag bolts to both mounts, something that will also have to be addressed. With the longer travel shocks I have and the reclocked shock mounts, I have about 4" of stuff and W A Y more droop-out.

So this is how I solved that...I designed a telescoping lower mount.
The air bag will indeed be bolted to one section of the lower mount, while the other part will attach to the axle. I designed it all to allow for all the droop-out I currently enjoy and with plenty of room for future growth.

Here's how it works. A simple set of 3.5" and 3" steel cylinders that fit together without actually touching except on the ends.
(http://i.imgur.com/ILPeWfL.jpg)
(http://i.imgur.com/U4eCbxa.jpg)
(http://i.imgur.com/frfrafB.jpg)
(http://i.imgur.com/M9EIw8N.jpg)
(http://i.imgur.com/rOrTfgR.jpg)

Here's just one of the sleeves used to support the air bag at resting height, then another view with the rear of the truck jacked up. You can see, there is another 3-4" of droop-out remaining in the design.
(http://i.imgur.com/BcYewT4.jpg)
(http://i.imgur.com/UwKMzmk.jpg)
(http://i.imgur.com/NhA6aej.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:39:55 PM
At this point the little rangers started complaining, wanting pizza, so my time was quickly drawing to a close.
I decided to paint up a couple parts then call it a night
(http://i.imgur.com/rxK6obK.jpg)

Here's what everything looked like at quitting time:
(http://i.imgur.com/YDl18kK.jpg)
(http://i.imgur.com/5Hzodjv.jpg)
(http://i.imgur.com/ZDRVukY.jpg)
(http://i.imgur.com/WuuLsvc.jpg)
(http://i.imgur.com/zX09OT9.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:41:06 PM
Quote:
Originally Posted by r*********
Lookin good Don. I'm not doubting your skills but from the looks of the pipe sleeves you are going to be using they look a little on the thin side for my liking. Not saying i'm a engineer or anything...well my job title leads people to think i'm a really one but anyways. When the axle comes up to put pressure on that sleeve and you have your foot on the go go pedal i might be worried that that sleeve might have some lateral pressure against it, causing it to fold? Just me lookin and thinkin. I don't have the whole picture wrapped around my head yet of exactly what your doing also. Just me thinkin.

You make a good point that is actually valid!
Not saying anything about the worthless, side tracking scribble from that DOT on the earlier post, but I'll address this one.

First on strength: I think it is way more than enough to carry the loades which won't be all that much. Remember that the springs are still there doing their spring thing. THis bag will carry maybe 500 pounds, like one seventh of it's design load. I plan to keep it at a lower pressure, probably around 20 pounds. THat will be sufficient to carry lots of extra weight and during the times when the axle extends, as the bag lengthens, the pressure will reduce quickly so that when it is free standing it won't blow itself apart.
Back to the strength. Monoque construction aircraft carry big loads, yet are normally constructed from materials .032" - .040" in thickness. They do that by making the circunference way big.
This material is of a sufficient diameter, (3.5") for the load carrying piece to accomodate what, 10 times the forces it will carry? So, with respect, it is way strong enough.

Robust: I see thickness of the support cylinder more an issue of being somewhat impact resistient. Down there in wheel well land, sometimes things go ah' flyin'
So the material ought to be able to stand up to that, but frankly, needs little more.
Torsional resistance: That is the $64,000 question! Right now we know the rear springs are wrapping and unwinding on hard accleration. Remember the photo of that happening in the driveway?
Well several things are going to come into play here. First is the "mall rattling, tin can sound effect" that the DOT mentioned earlier, which, like him is mostly nonsense! There is enough room in there for some pretty big angular dis-combobulation! Then lets remember all that is connected to
R U B B E R!!!
Which as Mr. GoodYear designed it to do, B E N D S!!!!!!!!
But, having said all that and of course taken some liberth on that hapless DOT member, I do want to do something about all that "Anti-Traction"
(New term there...I believe I can claim it's first use)
I plan to do that with either those new Atlas springs, or a contraption bar, or a combo of both.
So rest easy young man, and DOT's, go bother someone else, I think we's be ah-ight 
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:43:12 PM
Quote:
Originally Posted by stlaser
Maybe coat those cylinders with graphite paint, the stuff they use on grain hoppers. It works well for using between the leaf springs too (hint hint)......

Man we think so much alike!
That's exactly what I was going to use in there.
It's called "Slip Plate" a product sold at the John Deere store


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:46:03 PM
OK, let's finish up this air bag install.
It took a lot longer than I anticipated, but doesn't everything on this truck?

I'm just so meticulious that a 5 minute chore turns into a half hour study then another 45 min redesign followed by a 1 hour install. So it went with this "kit"

Anyway, before I even continued on the air bag install, I wanted to do something with the brake lines. I never did like how Fabtech raised everything up to look bad and expose those lines to the elements.

So I started by removing and lowering the upper brake hose to hard line attachment block. I also carefully bent it inward. Before when I jacked up the truck, that action acuually stretched the brake lines. Option 1 was to buy longer lines, but that turned out to be too big a task for two parts guys this morning.
So I applied some Don to it and now it looks different.
Here's stock, and with the line unbolted and bent inward:
(http://i.imgur.com/JOA0hMh.jpg)
(http://i.imgur.com/uC52Idv.jpg)
(http://i.imgur.com/bYw3slM.jpg)

I fashioned this weld-em-up bracket to relocate the hard line transition block about where it was hanging
(http://i.imgur.com/NugAXWl.jpg)
(http://i.imgur.com/8mKgWz2.jpg)

Next I removed all those unnecessary extension (Let's place the brake lines in harm's way) brackets.
(http://i.imgur.com/rm8vA47.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:48:32 PM
Next after fitting the lower mount, I sort of liked it, in a pre-modded sort of way.
Without further adieu, I cut the ears off, drilled 4 1/2" holes in the sides of each mount to later rose weld onto the axle pad, then chucked the things onto the floor.
(http://i.imgur.com/XgObgY9.jpg)
(http://i.imgur.com/qIiK9bA.jpg)
(http://i.imgur.com/bukvpBz.jpg)
(http://i.imgur.com/vaFyfOF.jpg)
(http://i.imgur.com/gc3T4T2.jpg)

Then they were welded in place
(http://i.imgur.com/BQGWeP3.jpg)
(http://i.imgur.com/dmkTQAJ.jpg)
(http://i.imgur.com/cvXyFyz.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:51:45 PM
If that weld looks like molten steel poured out of the hole, that's because, it did! I had the temp turned way up...I wanted that piece to be strong and trouble free.
Then I turned my attention to the upper brake transition block mount, welding that and painting with the good John Deere stuff.

With the brake lines back where Mr. GM intended them to be, things started to get much more tidy than Mr. Fabtech had thought about.
(http://i.imgur.com/fnbb4Is.jpg)
(http://i.imgur.com/O9Jxcu9.jpg)

Next, the bases were bolted to the airbags
(http://i.imgur.com/flg9tqM.jpg)
(http://i.imgur.com/otcx4Ht.jpg)
(http://i.imgur.com/q4FENxA.jpg)

I bolted the bags in place then moved them about until they found "home"

THen I traced the outline of the load bearing cylinger onto the lower bracket, then removed the bags.

After some grinding to remove the coating, the inner cylinders were positioned in the middle and welded into place.

Before welding them in place, I shortened them 1/2" to be sure they would not carry any of the load.
(http://i.imgur.com/VaSMfnJ.jpg)
(http://i.imgur.com/wGAynlQ.jpg)
(http://i.imgur.com/8OIGkjG.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 08:54:40 PM
(http://i.imgur.com/YrLfIuY.jpg)

Skipping back and forth between the bags and the brake lines, now was the time to lock all the lines down into place
(http://i.imgur.com/xKudkzG.jpg)

The air line fittings were installed
They pivot to any angle you need
(http://i.imgur.com/QtgIlpD.jpg)
(http://i.imgur.com/TxFUlZK.jpg)
(http://i.imgur.com/H4OyaNS.jpg)

Jacking up the truck allowed for easier installation of the air bag assembly
(http://i.imgur.com/9vlNpKn.jpg)

The right bag was permanently installed
(http://i.imgur.com/vUkoPvU.jpg)
(http://i.imgur.com/1SZY8je.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 09:25:50 PM
That's a heater hose which is acting as a guard for the semi exposed nylon air line.

The bags will maintain divorced air valves for the moment so I can apply asymetric loading to the rear suspension for fine tuning

The schrader valves went in just above the trailer electrical connection port
(http://i.imgur.com/weWheKw.jpg)
(http://i.imgur.com/q2TRkEL.jpg)
(http://i.imgur.com/rjzzdaz.jpg)

Here is the finished installation
(http://i.imgur.com/aFTBgk5.jpg)
(http://i.imgur.com/k1LB9Rd.jpg)
(http://i.imgur.com/RcwbOSw.jpg)
(http://i.imgur.com/58Zzj3V.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 09:27:37 PM
I started with adding 20psi of air.
That raised the rear nearly 3" !!!!!!!!!!

So I started experimenting with lower pressures
(http://i.imgur.com/i1DWiTs.jpg)

I finally settled in on 10psi in each bag for about 1.5" lift and still some pretty good flex.
(http://i.imgur.com/zqFr4nq.jpg)
(http://i.imgur.com/D3GoLQa.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 04, 2014, 09:30:25 PM
                                                                                                 (4963)

Quote:
Originally Posted by nmeyer414 View Post
If we only had the ability to design our vehicles the way we want them from the factory? Modding them would be so much easier.

Yea, like we could go to the dealer, then ala-carte the whole thing.
Hmmm, I'll take the diesel, but with two, err, no, three turbos and I'll pass on the tree hugger stuff.
I want a Dana 70 front a dana 92 rear. What, Dana doesn't make a model 92 yet??? Well have them design it and include 2" axles made of kryptonite and be full floating, ah just make it magnetic drive coupling
I'd like 23, naw, make it 36 MPG city and 200MPG highway. I'd like a crawl ratio of 1000:1 in my seven speed manual/auto/convertible trans and a 155mph top end. Let's give me 150 gallons of natural gas, sorry, I'm passing on the actual wet stuff for now, and I'd like to store all of that inside the frame!
Speaking of frames, make mine billet aluminum and please keep the weight under 100 pounds and still meet my MGVW of 30K. Please give me options for tires or tracks and lets lift it 8"
No, sorry, no radiator in this one, figure something out with the LNG, and instead of paint, just cover the entire vehicle with photoviolic solar cells. Could you make those is a star warsey camo pattern please.
Can I pick this up in a couple hours, I'm leaving on that trip around the world in the morning you know and I'll be driving.
Oh did I mention I need it to be amphibious? No, I won't be taking a plane. It is always a pleasure doing business with you, and can we spread the payments out over say 70 years, please keep the cost under a thousand dollars, and zero percent financing...In fact, just contact the energy department to let them know I have a solar cell covered vehicle and get a grant from them for the full amount!
Thank you very much!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 05, 2014, 09:28:03 AM
Quote:
Originally Posted by Armalite
Actually, 15 years from now, we will be looking back saying, " Remember when we could buy those diesel trucks? Remember how tough they were? I sure miss the old days when you could mod on them and do what you wanted with YOUR truck that you spend YOUR money on. Now all we have are these coke can bodies with a lawnmower motor and battery back ups..."

15 years from now we're likely to be saying, " I remember when we owned trucks! They weren't part of the collective...Back when the United States existed, before the liberals introduced socialism and the war started we lifed unafraid and free. None of these checkpoints and goverment safe areas we have today. There was no such thing as the wild country where the lawless and the patriots live. We had guns as well! Yes, we actually owned them. And they weren't instruments of war, just things we owned because we liked to...And we had houses. I don't believe there was a single refugee camp, and none of these foreign soldiers always shoving us around, nope, those were the good old days!"
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 05, 2014, 09:32:48 AM
Well, here's one thing that happened to me:
(http://i.imgur.com/l6owKcH.jpg)

That would be a 4720
66 horsepower, 60 at the PTO

I went down to look at the 3720 I was buying for the farm, It was a left over 2010 model...
A left over model which had been sitting in the sun for 2-3 years now.
Everything was faded
THey told me it was warrantied and would replace the faded parts
So I started my preflight and ended up with a full page of parts that needed to be replaced.
I offered them to buy the tractor after they replaced everything, or to discount the machine by the cost of parts and labor, or skip it all together
They opted for Door #3
Well we collectively did.
I started really accessing the work required down on the farm and no little anything is going to work down there.
I have about 10,000 cedar trees to take out. Enough actually to actually pay for the farm, at least what I paid for it!
Some of them are 24" and even bigger at the base!
They will make very pricey logs.
So all of that has to be cleared, along with about 30-40 acres of bush-hogging
THe fields now are grown over with 1-2" locust and cedars. I found a cutter, the deere MX-6 which is rated to munch up a 2" tree, so I added that in there
I added the 400X loader and put a 4-1 hydraulic bucket on it.
I'll use the tractor to pick up the tree.
I added a bunch of other stuff to it and ordered the M4 carbine mount for the roll bar.
After buying that I purchased a 9K trailer 6'10" X 18'
I sold all the tundra stuff
I cleaned out the garage, purchased 20 more yards of mulch
And
that is the problem!
They dumped the mulch too close to the garage
And
sadly
THe D-max is mired up to the frame!
I'm afraid, it's lost!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 05, 2014, 09:36:39 AM
Quote:
Originally Posted by KensAuto
Be nice to your elders Ash! He has already installed air bags to help with the bumper he's been hauling around for a while now. That thing has to weigh more than a 9k trailer. haha


Posted by Armalite:
I had different thoughts on the air bag theory...

See, he (Don) is starting to realize what a chore it will be to lift that spare tire up and down, or even the fuel/water cans. So, he is having atlas build him a custom set of leaf springs...

Then he installs the air bags...

I bet, at best, he will be able to decompress the bags, thus sitting the rear of the truck at least a foot or two closer to the pavement, via articulating rear springs. This way, he only has to exert a minimal amount of force to lift that spare and fuel/water cans. Almost like a bagged truck, but lifted with bags.

Need to load the spare, need to put that fuel can back into the rack, then simply release the air, lower the rear a few feet, load the spare, or the little rangers into the bed. Now, supply the bags with the required amount of air, and the truck is back at normal riding heights...


Posted by KensAuto:
.....or maybe the tractor will stay on the trailer, which will stay attached to the truck, so that the bucket is right above the spare at all times....vola, instant tire hoist. That would make the airbags part of the tractor-with-tire-in-bucket lower to the ground on command.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 05, 2014, 09:37:23 AM
Quote:
Originally Posted by BobbyB
Man the DOT's are relentless this morning..


What I was thinkin...
DOTs...

Ya know, I do something like install a second D-Max engine under the bed and add mag-levitation to the truck and what do I get...???
Silence...
Make one off the subject comment (DOT-like-activity, or DLA)
and I get seventeen more useless cat herding, gay and lesbian, progressive agenda advancin, worthless comments!
...Dots!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 10:27:42 AM
In reference to how many directions this build thread has taken:

Nate,
I took a stab at trying to chart the "Subject flow" here
I think I lost my ability to concentrate about the same time I ran out of ink
How'd I do?
(http://i.imgur.com/EtCTe0S.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 10:36:08 AM
Pressing forward on the whole Survival Focused Vehicle, SFV, as I now call it, I added to it's capability today with the following items.
It is getting quite heavy so adding on the hi-lift jack was going to add that much weight, but the real problem is that with the system I was planning to use I would start with the 48" jack more than 3/4ths extended. Then if I was jacking the rear wheel, I wonder if it would even lift the wheel off the ground off the ground
So I opted for something unusual, an air bag jack, that could be inflated with compressed air, CO2 or exhaust gases.
Secondly since I will have to ferry fuel down to Big Red on a regular basis, I ordered a handy 5-Pack of those great NATO fuel cans. I think I'll build a fack on the front of the trailer to secure them, then bold down a tool box right in front of all that.
When not hauling tractors and such, I'll transfer those fuel cans all over. I now have 9 of the NATO cans and 1 Blitz which is red and dedicated to gasoline.
(http://i.imgur.com/hZVGuDS.jpg)
(http://i.imgur.com/Y5BWjzY.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 10:58:07 AM
OK, I am also in the middle of relocating things on the truck frame to make room for some coming additions and make the space more useable.
I planned on shortening up the exhaust some and creating a side exit.
I wasn't 100% sure how I would attack it, but thought I'd just mount the muffler as far forward as possible then bring a 4" pipe out the side right in front of the front leaf spring mount. There is a deeply recessed area there that provides some pretty good protection for the pipe and allows one to tuck it up nice and tight.
I am absolutely amazed at how well this turned out! The MBRP pipe has a section which almost bolts in place and literally looks like they intended it to be a side exit tail pipe.
Judge for yourself.

So we begin by getting everything out of there:
(http://i.imgur.com/WtG2YNH.jpg)
(http://i.imgur.com/8w6hq7i.jpg)
(http://i.imgur.com/eIQ9flO.jpg)
(http://i.imgur.com/PhSNHyY.jpg)

With the parts out, I cut off the no longer used muffler mounts which I welded on a year or so ago
(http://i.imgur.com/nU0kd2D.jpg)
(http://i.imgur.com/nU0kd2D.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 11:12:23 AM
                                                                                  (5536)
The removal of the tailpipe really freed up space around back.
Underneath here is the start-build point.
(http://i.imgur.com/I9qsxU6.jpg)
(http://i.imgur.com/noyQrAs.jpg)
(http://i.imgur.com/8JRn3CL.jpg)
(http://i.imgur.com/LxN5lL6.jpg)

Then in a flash the muffler was repositioned and placed where it would soon call home:
(http://i.imgur.com/4EULfOS.jpg)

This pipe used to be the "Over the hump" piece that resided above the rear axle.
It is perfect for sliding into the muffler outlet with about 3" of trimming and becoming a tailpipe.
Here's about where it will go:
(http://i.imgur.com/LJKWa41.jpg)
(http://i.imgur.com/0XnjVWd.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:00:42 PM
To secure the muffler, I bent up a piece of 1/2" steel rod to wrap around and be welded to the muffler and slide into an existing hanger.
(http://i.imgur.com/O9DmyE0.jpg)
(http://i.imgur.com/F3zqzXe.jpg)
(http://i.imgur.com/Oyj8Gvg.jpg)
(http://i.imgur.com/4rXb9M5.jpg)

MBRP sets up the flared sections of pipe to capture 3.5" of inner pipe, so I marked everything to make sure I was getting full depth:
(http://i.imgur.com/L97zuyt.jpg)
(http://i.imgur.com/jt6IXa0.jpg)

Some scotchbrite did a great job of cleaning up the mating surfaces. With the muffler clamped in place, the hanger was welded to it to carry the load:
(http://i.imgur.com/sIn7pWD.jpg)
(http://i.imgur.com/OipJrsn.jpg)
(http://i.imgur.com/GG0fHqb.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:03:31 PM
With a little of the exit pipe trimmed away the thing slid in the muffler like it was designed to. I noticed it sat about an inch too far aft, so I cut away another inch and got a perfect alignment!
Man I'm liking how this is coming together!
(http://i.imgur.com/MYRIh8j.jpg)
(http://i.imgur.com/656VPcJ.jpg)
(http://i.imgur.com/J6AemUh.jpg)
(http://i.imgur.com/VQcLyaM.jpg)

Some more views of how I'm thinking it will fit in there:
(http://i.imgur.com/3fpNpwc.jpg)
(http://i.imgur.com/Zsa6ely.jpg)
(http://i.imgur.com/RsyIhTW.jpg)
(http://i.imgur.com/udgMFnV.jpg)
(http://i.imgur.com/uFqxT9Y.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:06:35 PM
That looks really close, but it isn't. I have at least an inch everywhere!

Next I considered how to hange this pipe. There was a factory hanger just above the exit! Can you believe that, so I unbolted it, reversed it and rehung it in the factory spot!
(http://i.imgur.com/QeP7Y6K.jpg)
(http://i.imgur.com/50EEX1X.jpg)

Now it started with one rubber dog-bone isolator which could hold the pipe up. I wanted to secure it fore and aft to be sure it wouldn't rattle on anything, so I simply used a second dog-bone isolator on the same mount.
The concept here is to have them opposing each other in orientation, one aft, one forward, and here's how that worked out:
(http://i.imgur.com/9LtqhMH.jpg)
(http://i.imgur.com/rrTfCUl.jpg)
(http://i.imgur.com/DM4VVWb.jpg)

Next came the hanger rods all bent up and looking like they belonged there:
(http://i.imgur.com/9BEW7Wo.jpg)
(http://i.imgur.com/gspbwrz.jpg)
(http://i.imgur.com/6nifrbo.jpg)
(http://i.imgur.com/p0jAugQ.jpg)
(http://i.imgur.com/jBMBU1y.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:08:51 PM
Not very long time wise into this project and it is getting done! This was an easy and rewarding project!
I pulled the pipe off to final weld the hangars, and heat the rods and shape them onto the pipe a little better.
Look at all the space that I freed up behind the new tailpipe:
(http://i.imgur.com/x7DXgmL.jpg)
(http://i.imgur.com/PGdXGP8.jpg)
(http://i.imgur.com/jppOjEE.jpg)
(http://i.imgur.com/sG2IXcB.jpg)

Clean up and paint time.
Everything got wire brushed, wiped with laquer thinner, then given a coat of self etching primer, then a second coat of John Deere Blitz-Black.
(http://i.imgur.com/0iNpPtZ.jpg)
(http://i.imgur.com/BzfmNV0.jpg)
(http://i.imgur.com/SmCCGB9.jpg)

These pieces were discarded since they are no longer a part of the plan!
(http://i.imgur.com/Aapggwl.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:11:12 PM
Here's a shot of the freshly dried pipe reinstalled
(http://i.imgur.com/VFREFKN.jpg)

(http://i.imgur.com/WIYDi5k.jpg)

(http://i.imgur.com/JU8YYYy.jpg)

(http://i.imgur.com/yRAQCCu.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:28:49 PM
I finished the articulating hitch and by all reasoning I think it is a monster. But enough of you had misgivings that I thought I'd buy a Reese 10K plug-in Pintle and weld up a swiveling Lunette and try that as well.
The beauty of the reciever hitch on both the truck and the trailer allows me to use any connecting device I wish.
I had it in there for fit and interference testing.
All I'd say, is that Reese has the thing sticking too far out the back. If I keep it, I'll shove it in a few inches and redrill the hole...should make it stronger as well.
(http://i.imgur.com/8rcBF7S.jpg)
(http://i.imgur.com/nfMtaw3.jpg)
(http://i.imgur.com/xHIXrGP.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:31:30 PM
Well we pushed the project another couple feet down field today.
I ran into an issue with the articulating hitch...It's darned hard to get fitted into either reciever. THere is some percise formation flying required to get alignment, so I thought I'd develop the pintle concept more.

You boneheads might recall that I purchased that Reese 10,000 lb capacity pintle that slides in the reciever. Well, I liked about a third of that idea.
I liked ease of installation and the pintle thing and the fact that it is black!
I did not like:
1. that it was only rated at 10,000 lbs, same same as my trailer
2. Made in China
3. Doesn't swivel
4. Made in China

With that in mind I went off pintle shopping and came up with a whole cat's arm full of towing stuff just begging for some cuttin' weldin' and modifin'

Here's what I started with this morning:
(http://i.imgur.com/FgoQeMS.jpg)

The Reese pintle has Gator build written all over it, so that's where it is headed

The new pintle is a bolt on thing that is rated at 15 tons or 30,000 pounds or 28,996 royal pounds (Just kidding, there is no such thing, but with our current education system, I could say just about anything and few would notice!

Also cast right into the side of the thing were three of my favorite letters:
U S A, as in made in the USA. Now that made this thing a keeper right off the git-go!
(http://i.imgur.com/MfROQUU.jpg)
(http://i.imgur.com/czOCVvv.jpg)
(http://i.imgur.com/93shrNZ.jpg)
(http://i.imgur.com/uEwpm0n.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:33:04 PM
You guys may not like the blurry pictures, but I don't care, I do. You see they sync up with my normal near vision (That is to say you could nearly call it vision!)

The pintle mount manufacturers were kind enough to supply me a flange along with a mount, but they had it all welded and forged together. My new friend, Mr. HyperTherm changed all that PDQ
With some cuttin' and generatin' of that smoke that is inside of everything, I had this, the swivel piece part:
(http://i.imgur.com/D9JUZp6.jpg)
(http://i.imgur.com/x0vBFRw.jpg)

Never mind the fly swatter, err, brass hammer, it was just there for me to wonder about.

This is about how it will all fit together:

That inner piece took nearly all of what my 30 ton press could deliver to seat that section reducer and strengthener into the 2" X .250 wall outer tube. Total thickness of the base is right at 1/2" wall!
(http://i.imgur.com/KOA0Fk3.jpg)
(http://i.imgur.com/dGH1XfM.jpg)
(http://i.imgur.com/SHlzZox.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:38:45 PM
The idea this time is to make the pintle a revolver. I used the same 1" diameter, 8" long grade 8 bolts to provide the swivel mechanism. The multi washers are the slip surfaces and serve to hold everything square and store motorcycle chain lube.
Once I bolted the two parts together, even with substantial guten-tight torque, it all still swiveled...Cool, because if it didn't that would be un-cool!

Then for extra measure I sank a 5/8" drill through both square tubes and about a 1/8" into the bolt itself, then plug welded it all together. No sir, that bolt will not be coming out very easily

So here's what it ended up looking like on the miller welder assembly bench
(http://i.imgur.com/Zwi4RCR.jpg)
(http://i.imgur.com/liWjRSv.jpg)
(http://i.imgur.com/Bbqtg8e.jpg)

Those are 1/2" grade 8 bolts and 466 washers used to space the backside of the pintle far away enough from the bolt head. I have about one peperoni slice thickness to work with there!
(http://i.imgur.com/rWDOxeT.jpg)
(http://i.imgur.com/0qggzcX.jpg)
(http://i.imgur.com/hiRdKYF.jpg)
(http://i.imgur.com/KB9s9hP.jpg)

Swivels up a bunch! Gave me vertigo just posting it up!

the bottom of the pintle saddle sits at 24"

Measuring the junette on the trailer, when the trailer is dead level, it also sits at 24"

Ya know, sometimes you're just livin right!!!
(http://i.imgur.com/ehdB8SI.jpg)
(http://i.imgur.com/SNbnivp.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 2-EGR delete and more]
Post by: KensAuto on December 07, 2014, 04:41:10 PM
Next, we're off to the trailer again to get that Lunette ring welded on. It is rated for 9,000 tongue weight and a trailer weight of 42,000lbs, so it should be up to the task at hand.

Off with the old (Not so old) and on with the new:
(http://i.imgur.com/8wJwpZL.jpg)
(http://i.imgur.com/Sy3M0Td.jpg)
(http://i.imgur.com/Vf2YE8j.jpg)
(http://i.imgur.com/a7htdUI.jpg)
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